Method and apparatus for forming a mono-diameter wellbore casing

CROSS REFERENCE TO RELATED APPLICATIONS

0001This application is a divisional of U.S. application Ser. No. 10/465,831, filed Jun. 13, 2003 now U.S. Pat. No. 7,100,685, which is the National Stage filing of the International Application No. PCT/US02/00093, filed Jan. 2, 2002 which is based on U.S. application Ser. No. 60/259,486, filed on Jan. 3, 2001, which was a Continuation-In-Part of U.S. application Ser. No. 10/406,648 filed Mar. 31, 2003, which is a National Phase of the International Application No. PCT/US01/30256, filed Sep. 27, 2001 which is based on U.S. Application Ser. No. 60/237,334, filed on Oct. 2, 2000, the disclosure of which is incorporated herein by reference.

0002This application is related to the following applications: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, now U.S. Pat. No. 6,497,289, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09,502,350, filed on Feb. 10, 2000, now U.S. Pat. No. 6,823,937 (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, now U.S. Pat. No. 6,328,113 (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, now U.S. Pat. No. 6,640,903 (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, now U.S. Pat. No. 6,568,471 (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, now U.S. Pat. No. 6,575,240 (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, now U.S. Pat. No. 6,557,640 (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, now U.S. Pat. No. 6,604,763 (10) PCT patent application serial no. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. Pat. No. 6,564,875, which was filed as application Ser. No. 09/679,907, on Oct. 5, 2000, which claims priority from U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. patent application Ser. No. 10/089,419, filed on Mar. 27, 2002, now U.S. Pat. No. 6,695,012 which issued Feb. 24, 2004, which claims priority from U.S. provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, (20) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22, 2003, now U.S. Pat. No. 6,976,541 which issued Dec. 20, 2005, which claims priority from U.S. provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, and (21) U.S. provisional patent application Ser. No. 60/237,334, filed on Oct. 2, 2000. Applicants incorporate by reference the disclosures of these applications.

0003This application is also related to each of the following: (1) U.S. patent application Ser. No. 11/068,595, filed on Feb. 28, 2005; (2) U.S. patent application Ser. No. 11/070,147, filed on Mar. 2, 2005; (3) U.S. patent application Ser. No. 11/071,409, filed on Mar. 2, 2005; (4) U.S. patent application Ser. No. 11/071,557, filed on Mar. 3, 2005; (5) U.S. patent application Ser. No. 11/072,578, filed on Mar. 4, 2005; (6) U.S. patent application Ser. No. 11/072,893, filed on Mar. 4, 2005; (7) U.S. patent application Ser. No. 11/072,594, filed on Mar. 4, 2005, (8) U.S. patent application Ser. No. 11/074,366, filed on Mar. 7, 2005; and (9) U.S. patent application Ser. No. 11/074,266, filed on Mar. 7, 2005.

0004This application is related to the following applications: (1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, which claims priority from provisional application 60/121,702, filed on Feb. 25, 1999, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, now U.S. Pat. No. 6,823,937 which issued Nov. 30, 2004, which claims priority from provisional application 60/119,611, filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434, filed on Jul. 1, 2002, which claims priority from provisional application 60/183,546, filed on Feb. 18, 2000, (6) U.S. Pat. No. 6,640,903 which was filed as U.S. patent application Ser. No. 09/523,468, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (8) U.S. Pat. No. 6,575,240, which was filed as patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,907, filed on Feb. 26, 1999, (9) U.S. Pat. No. 6,557,640, which was filed as patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, which claims priority from provisional application 60/137,998, filed on Jun. 7, 1999, (10) U.S. patent application Ser. No. 09/981,916, filed on Oct. 18, 2001 as a continuation-in-part application of U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (11) U.S. Pat. No. 6,604,763, which was filed as application Ser. No. 09/559,122, filed on Apr. 26, 2000, which claims priority from provisional application 60/131,106, filed on Apr. 26, 1999, (12) U.S. patent application Ser. No. 10/030,593, filed on Jan. 8, 2002, which claims priority from provisional application 60/146,203, filed on Jul. 29, 1999, (13) U.S. provisional patent application Ser. No. 60/143,039, filed on Jul. 9, 1999, (14) U.S. patent application Ser. No. 10/111,982, filed on Apr. 30, 2002, which claims priority from provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (15) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (16) U.S. provisional patent application Ser. No. 60/438,828, filed on Jan. 9, 2003, (17) U.S. Pat. No. 6,564,875, which was filed as application Ser. No. 09/679,907, on Oct. 5, 2000, which claims priority from provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (18) U.S. patent application Ser. No. 10/089,419, filed on Mar. 27, 2002, now U.S. Pat. No. 6,695,012 which issued Feb. 24, 2004, which claims priority from provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (19) U.S. patent application Ser. No. 09/679,906, filed on Oct. 5, 2000, which claims priority from provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (20) U.S. patent application Ser. No. 10/303,992, filed on Nov. 22, 2002, which claims priority from provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (21) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (22) U.S. provisional patent application Ser. No. 60/455,051, filed on Mar. 14, 2003, (23) PCT application US02/2477, filed on Jun. 26, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/303,711, filed on Jul. 6, 2001, (24) U.S. patent application Ser. No. 10/311,412, filed on Dec. 12, 2002, which claims priority from provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (25) U.S. patent application Ser. No. 10/, filed on Dec. 18, 2002, which claims priority from provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, (26) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22, 2003, now U.S. Pat. No. 6,976,541 which issued Dec. 20, 2005, which claims priority from provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, (27) U.S. patent application Ser. No. 10/406,648, filed on Mar. 31, 2003, which claims priority from provisional patent application Ser. No. 60/237,334, filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on Feb. 14, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/270,007, filed on Feb. 20, 2001, (29) U.S. patent application Ser. No. 10/465,835, filed on Jun. 13, 2003, which claims priority from provisional patent application Ser. No. 60/262,434, filed on Jan. 17, 2001, (30) U.S. patent application Ser. No. 10/465,831, filed on Jun. 13, 2003, which claims priority from U.S. provisional patent application Ser. No. 60/259,486, filed on Jan. 3, 2001, (31) U.S. provisional patent application Ser. No. 60/452,303, filed on Mar. 5, 2003, (32) U.S. Pat. No. 6,470,966, which was filed as patent application Ser. No. 09/850,093, filed on May 7, 2001, as a divisional application of U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. 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BACKGROUND OF THE INVENTION

0005This invention relates generally to wellbore casings, and in particular to wellbore casings that are formed using expandable tubing.

0006Conventionally, when a wellbore is created, a number of casings are installed in the borehole to prevent collapse of the borehole wall and to prevent undesired outflow of drilling fluid into the formation or inflow of fluid from the formation into the borehole. The borehole is drilled in intervals whereby a casing which is to be installed in a lower borehole interval is lowered through a previously installed casing of an upper borehole interval. As a consequence of this procedure the casing of the lower interval is of smaller diameter than the casing of the upper interval. Thus, the casings are in a nested arrangement with casing diameters decreasing in downward direction. Cement annuli are provided between the outer surfaces of the casings and the borehole wall to seal the casings from the borehole wall. As a consequence of this nested arrangement a relatively large borehole diameter is required at the upper part of the wellbore. Such a large borehole diameter involves increased costs due to heavy casing handling equipment, large drill bits and increased volumes of drilling fluid and drill cuttings. Moreover, increased drilling rig time is involved due to required cement pumping, cement hardening, required equipment changes due to large variations in hole diameters drilled in the course of the well, and the large volume of cuttings drilled and removed.

0007The present invention is directed to overcoming one or more of the limitations of the existing procedures for forming wellbores.

SUMMARY OF THE INVENTION

0008According to one aspect of the invention, an apparatus for plastically deforming and radially expanding a tubular member is provided that includes means for plastically deforming and radially expanding a first portion of the tubular member to a first outside diameter, and means for plastically deforming and radially expanding a second portion of the tubular member to a second outside diameter.

0009According to another aspect of the present invention, an apparatus for plastically deforming and radially expanding a tubular member is provided that includes a tubular support member including a first fluid passage, an expansion cone coupled to the tubular support member having a second fluid passage fluidicly coupled to the first fluid passage and an outer conical surface, a removable annular conical sleeve coupled to the outer conical surface of the expansion cone, an annular expansion cone launcher coupled to the conical sleeve and a lower portion of the tubular member, and a shoe having a valveable passage coupled to an end of the expansion cone launcher.

0010According to another aspect of the present invention, a method of plastically deforming and radially expanding a tubular member is provided that includes plastically deforming and radially expanding a portion of the tubular member to a first outside diameter, and plastically deforming and radially expanding another portion of the tubular member to a second outside diameter.

0011According to another aspect of the present invention, a method of coupling a first tubular member to a second tubular member is provided that includes plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter, plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter, positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member, plastically deforming and radially expanding the second tubular member to a third outside diameter, and plastically deforming and radially expanding the second tubular member to a fourth outside diameter. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal.

0012According to another aspect of the present invention, an apparatus for coupling a first tubular member to a second tubular member is provided that includes means for plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter, means for plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter, means for positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member, means for plastically deforming and radially expanding the second tubular member to a third outside diameter, and

0013means for plastically deforming and radially expanding the second tubular member to a fourth outside diameter. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal.

0014According to another aspect of the present invention, an apparatus for forming a wellbore casing within a wellbore is provided that includes means for supporting a tubular member within the wellbore, means for plastically deforming and radially expanding a first portion of the tubular member to a first outside diameter, and means for plastically deforming and radially expanding a second portion of the tubular member to a second outside diameter.

0015According to another aspect of the present invention, an apparatus for forming a wellbore casing within a wellbore is provided that includes a tubular support member including a first fluid passage, an expansion cone coupled to the tubular support member having a second fluid passage fluidicly coupled to the first fluid passage and an outer conical surface, a removable annular conical sleeve coupled to the outer conical surface of the expansion cone, an annular expansion cone launcher coupled to the conical sleeve and a lower portion of the tubular member, and a shoe having a valveable passage coupled to an end of the expansion cone launcher.

0016According to another aspect of the present invention, a method of forming a wellbore casing within a wellbore is provided that includes supporting a tubular member within a wellbore, plastically deforming and radially expanding a portion of the tubular member to a first outside diameter, and plastically deforming and radially expanding another portion of the tubular member to a second outside diameter.

0017According to another aspect of the present invention, a method of forming a mono-diameter wellbore casing within a wellbore is provided that includes supporting a first tubular member within the wellbore, plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter, plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter, positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member, plastically deforming and radially expanding the second tubular member to a third outside diameter, and plastically deforming and radially expanding the second tubular member to a fourth outside diameter. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal.

0018According to another aspect of the present invention, an apparatus for coupling a first tubular member to a second tubular member is provided that includes means for plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter, means for plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter, means for positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member, means for plastically deforming and radially expanding the second tubular member to a third outside diameter, and

0019means for plastically deforming and radially expanding the second tubular member to a fourth outside diameter. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal.

0020According to another aspect of the present invention, an apparatus for plastically deforming and radially expanding a tubular member is provided that includes means for providing a lipped portion in a portion of the tubular member, and means for plastically deforming and radially expanding another portion of the tubular member.

0021According to another aspect of the present invention, an apparatus for plastically deforming and radially expanding a tubular member is provided that includes a tubular support member including a first fluid passage, an expansion cone coupled to the tubular support member having a second fluid passage fluidicly coupled to the first fluid passage and an outer conical surface, an annular expansion cone launcher including: a first annular portion coupled to a lower portion of the tubular member, a second annular portion coupled to the first annular portion that mates with the outer conical surface of the expansion cone, a third annular portion coupled to the second annular portion having a first outside diameter, and a fourth annular portion coupled to the third annular portion having a second outside diameter, wherein the second outside diameter is less than the first outside diameter, and a shoe having a valveable passage coupled to fourth annular portion of the expansion cone launcher.

0022According to another aspect of the present invention, a method of plastically deforming and radially expanding a tubular member is provided that includes providing a lipped portion in a portion of the tubular member, and plastically deforming and radially expanding another portion of the tubular member.

0023According to another aspect of the present invention, a method of coupling a first tubular member to a second tubular member is provided that includes providing a lipped portion in a portion of the first tubular member, plastically deforming and radially expanding another portion of the first tubular member, positioning the second tubular member inside the first tubular member in overlapping relation to the lipped portion of the first tubular member, and plastically deforming and radially expanding the second tubular member. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal.

0024According to another aspect of the present invention, an apparatus for coupling a first tubular member to a second tubular member is provided that includes means for providing a lipped in the first tubular member, means for plastically deforming and radially expanding another portion of the first tubular member, means for positioning the second tubular member inside the first tubular member in overlapping relation to the lipped portion of the first tubular member, and means for plastically deforming and radially expanding the second tubular member. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal.

0025According to another aspect of the present invention, an apparatus for forming a wellbore casing within a wellbore is provided that includes means for supporting a tubular member within the wellbore, means for providing a lipped portion in the tubular member, and means for plastically deforming and radially expanding another portion of the tubular member to a second outside diameter.

0026According to another aspect of the present invention, an apparatus for forming a wellbore casing within a wellbore is provided that includes a tubular support member including a first fluid passage, an expansion cone coupled to the tubular support member having a second fluid passage fluidicly coupled to the first fluid passage and an outer conical surface, an annular expansion cone launcher including: a first annular portion coupled to a lower portion of the tubular member, a second annular portion coupled to the first annular portion that mates with the outer conical surface of the expansion cone, a third annular portion coupled to the second annular portion having a first outside diameter, and a fourth annular portion coupled to the third annular portion having a second outside diameter, wherein the second outside diameter is less than the first outside diameter, and a shoe having a valveable passage coupled to fourth annular portion of the expansion cone launcher.

0027According to another aspect of the present invention, a method of forming a wellbore casing in a wellbore is provided that includes supporting a tubular member within the wellbore, providing a lipped portion in a portion of the tubular member, and plastically deforming and radially expanding another portion of the tubular member.

0028According to another aspect of the present invention, a method of forming a mono-diameter wellbore casing within a wellbore is provided that includes supporting a first tubular member within the wellbore, providing a lipped portion in a portion of the first tubular member, plastically deforming and radially expanding another portion of the first tubular member, positioning the second tubular member inside the first tubular member in overlapping relation to the lipped portion of the first tubular member, and plastically deforming and radially expanding the second tubular member. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal.

0029According to another aspect of the present invention, an apparatus for forming a mono-diameter wellbore casing within a wellbore is provided that includes means for providing a lipped in the first tubular member, means for plastically deforming and radially expanding another portion of the first tubular member, means for positioning the second tubular member inside the first tubular member in overlapping relation to the lipped portion of the first tubular member, and means for plastically deforming and radially expanding the second tubular member. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal.

0030According to another aspect of the present invention, an apparatus for plastically deforming and radially expanding a tubular member is provided that includes means for plastically deforming and radially expanding a first end of the tubular member, and means for plastically deforming and radially expanding a second end of the tubular member.

0031According to another aspect of the present invention, an apparatus for plastically deforming and radially expanding a tubular member is provided that includes a tubular support member including a first passage, an expansion cone coupled to the tubular support having a second passage fluidicly coupled to the first passage and an outer conical surface, an annular expansion cone launcher movably coupled to outer conical surface of the expansion cone, an expandable tubular member coupled to an end of the annular expansion cone launcher, a shoe coupled to another end of the annular expansion cone launcher having a valveable fluid passage, and another annular expansion cone movably coupled to the tubular support member. The annular expansion cones are positioned in opposite orientations.

0032According to another aspect of the present invention, a method of plastically deforming and radially expanding a tubular member is provided that includes plastically deforming and radially expanding a first end of the tubular member, and plastically deforming and radially expanding a second end of the tubular member.

0033According to another aspect of the present invention, a method of coupling a first tubular member to a second tubular member is provided that includes positioning the second tubular member inside the first tubular member in an overlapping relationship, plastically deforming and radially expanding the end of the second tubular member that overlaps with the first tubular member, and plastically deforming and radially expanding the remaining portion of the second tubular member.

0034According to another aspect of the present invention, an apparatus for coupling a first tubular member to a second tubular member is provided that includes means for positioning the second tubular member inside the first tubular member in an overlapping relationship, means for plastically deforming and radially expanding the end of the second tubular member that overlaps with the first tubular member, and means for plastically deforming and radially expanding the remaining portion of the second tubular member.

0035According to another aspect of the present invention, an apparatus for forming a wellbore casing within a wellbore is provided that includes means for supporting a tubular member within the wellbore, means for plastically deforming and radially expanding a first end of the tubular member, and means for plastically deforming and radially expanding a second end of the tubular member.

0036According to another aspect of the present invention, an apparatus for forming a wellbore casing within a wellbore is provided that includes a tubular support member including a first passage, an expansion cone coupled to the tubular support having a second passage fluidicly coupled to the first passage and an outer conical surface, an annular expansion cone launcher movably coupled to outer conical surface of the expansion cone, an expandable tubular member coupled to an end of the annular expansion cone launcher, a shoe coupled to another end of the annular expansion cone launcher having a valveable fluid passage, and another annular expansion cone movably coupled to the tubular support member. The annular expansion cones are positioned in opposite orientations.

0037According to another aspect of the present invention, a method of forming a wellbore casing within a wellbore is provided that includes plastically deforming and radially expanding a first end of the tubular member, and plastically deforming and radially expanding a second end of the tubular member.

0038According to another aspect of the present invention, a method of forming a wellbore casing within a wellbore is provided that includes plastically deforming and radially expanding a first tubular member within the wellbore, positioning a second tubular member inside the first tubular member in an overlapping relationship, plastically deforming and radially expanding the end of the second tubular member that overlaps with the first tubular member, and plastically deforming and radially expanding the remaining portion of the second tubular member.

0039According to another aspect of the present invention, an apparatus for forming a wellbore casing within a wellbore is provided that includes means for plastically deforming and radially expanding a first tubular member within the wellbore, means for positioning the second tubular member inside the first tubular member in an overlapping relationship, means for plastically deforming and radially expanding the end of the second tubular member that overlaps with the first tubular member, and means for plastically deforming and radially expanding the remaining portion of the second tubular member.

0040According to another aspect of the present invention, an apparatus for bridging an axial gap between opposing pairs of wellbore casing within a wellbore is provided that includes means for supporting a tubular member in overlapping relation to the opposing ends of the wellbore casings, means for plastically deforming and radially expanding the tubular member, and

0041means for plastically deforming and radially expanding the tubular member and the opposing ends of the wellbore casings.

0042According to another aspect of the present invention, a method of bridging an axial gap between opposing pairs of wellbore casing within a wellbore is provided that includes supporting a tubular member in overlapping relation to the opposing ends of the wellbore casings, plastically deforming and radially expanding the tubular member, and plastically deforming and radially expanding the tubular member and the opposing ends of the wellbore casings.

0043According to another aspect of the present invention, a method of forming a structure having desired strength characteristics is provided that includes providing a first tubular member, and plastically deforming and radially expanding additional tubular members onto the interior surface of the first tubular member until the desired strength characteristics are achieved.

0044According to another aspect of the present invention, a method of forming a wellbore casing within a wellbore having desired strength characteristics is provided that includes plastically deforming and radially expanding a first tubular member within the wellbore, and plastically deforming and radially expanding additional tubular members onto the interior surface of the first tubular member until the desired strength characteristics are achieved.

0045According to another aspect of the present invention, a method of coupling a first tubular member to a second tubular member, the first tubular member having an original outside diameter OD₀and an original wall thickness t₀, is provided that includes plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter, plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter, positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member, plastically deforming and radially expanding the second tubular member to a third outside diameter, and plastically deforming and radially expanding the second tubular member to a fourth outside diameter. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal, and the ratio of the original outside diameter OD₀of the first tubular member to the original wall thickness t₀of the first tubular member is greater than or equal to 16.

0046According to another aspect of the present invention, a method of forming a mono-diameter wellbore casing is provided that includes positioning a first tubular member within a wellbore, the first tubular member having an original outside diameter OD₀and an original wall thickness t₀, plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter, plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter, positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member, plastically deforming and radially expanding the second tubular member to a third outside diameter, and plastically deforming and radially expanding the second tubular member to a fourth outside diameter. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal, and the ratio of the original outside diameter OD₀of the first tubular member to the original wall thickness t₀of the first tubular member is greater than or equal to 16.

0047According to another aspect of the present invention, an apparatus is provided that includes a plastically deformed and radially expanded tubular member having a first portion having a first outside diameter and a remaining portion having a second outside diameter. The ratio of the original outside diameter OD₀of the first tubular member to the original wall thickness t₀of the first tubular member is greater than or equal to 16.

0048According to another aspect of the present invention, an apparatus is provided that includes a plastically deformed and radially expanded first tubular member having a first portion having a first outside diameter and a remaining portion having a second outside diameter, and a plastically deformed and radially expanded second tubular member coupled to the first portion of the first tubular member. The ratio of the original outside diameter OD₀of the first tubular member to the original wall thickness t₀of the first tubular member is greater than or equal to 16.

0049According to another aspect of the present invention, a wellbore casing formed in a wellbore is provided that includes a plastically deformed and radially expanded first tubular member having a first portion having a first outside diameter and a remaining portion having a second outside diameter, and a plastically deformed and radially expanded second tubular member coupled to the first portion of the first tubular member. The ratio of the original outside diameter OD₀of the first tubular member to the original wall thickness t₀of the first tubular member is greater than or equal to 16.

0050According to another aspect of the present invention, an apparatus is provided that includes a plastically deformed and radially expanded tubular member. The ratio of the original outside diameter OD₀of the tubular member to the original wall thickness t₀of the tubular member is greater than or equal to 16.

BRIEF DESCRIPTION OF THE DRAWINGS

0051<figref idref="DRAWINGS">FIG. 1</figref><i>a </i>is a cross sectional illustration of a wellbore including a preexisting wellbore casing.

0052<figref idref="DRAWINGS">FIG. 1</figref><i>b </i>is a cross-sectional illustration of the placement of an embodiment of an apparatus for radially expanding a tubular member into the wellbore of <figref idref="DRAWINGS">FIG. 1</figref><i>a. </i>

0053<figref idref="DRAWINGS">FIG. 1</figref><i>c </i>is a cross-sectional illustration of the injection of fluidic materials through the apparatus of <figref idref="DRAWINGS">FIG. 1</figref><i>b. </i>

0054<figref idref="DRAWINGS">FIG. 1</figref><i>d </i>is a cross-sectional illustration of the injection of hardenable fluidic sealing materials through the apparatus of <figref idref="DRAWINGS">FIG. 1</figref><i>c. </i>

0055<figref idref="DRAWINGS">FIG. 1</figref><i>e </i>is a cross-sectional illustration of the pressurization of the region below the expansion cone of the apparatus of <figref idref="DRAWINGS">FIG. 1</figref><i>d. </i>

0056<figref idref="DRAWINGS">FIG. 1</figref><i>f </i>is a cross-sectional illustration of the continued pressurization of the region below the expansion cone of the apparatus of <figref idref="DRAWINGS">FIG. 1</figref><i>e. </i>

0057<figref idref="DRAWINGS">FIG. 1</figref><i>g </i>is a cross-sectional illustration of the continued pressurization of the region below the expansion cone of the apparatus of <figref idref="DRAWINGS">FIG. 1</figref><i>f </i>following the removal of the over-expansion sleeve.

0058<figref idref="DRAWINGS">FIG. 1</figref><i>h </i>is a cross-sectional illustration of the completion of the radial expansion of the expandable tubular member of the apparatus of <figref idref="DRAWINGS">FIG. 1</figref><i>g. </i>

0059<figref idref="DRAWINGS">FIG. 1</figref><i>i </i>is a cross-sectional illustration of the drilling out of a new section of the wellbore below the apparatus of <figref idref="DRAWINGS">FIG. 1</figref><i>h. </i>

0060<figref idref="DRAWINGS">FIG. 1</figref><i>j </i>is a cross-sectional illustration of the radial expansion of another expandable tubular member that overlaps with the apparatus of <figref idref="DRAWINGS">FIG. 1</figref><i>i. </i>

0061<figref idref="DRAWINGS">FIG. 1</figref><i>k </i>is a cross-sectional illustration of the secondary radial expansion of the other expandable tubular member of the apparatus of <figref idref="DRAWINGS">FIG. 1</figref><i>l. </i>

0062<figref idref="DRAWINGS">FIG. 1</figref><i>l </i>is a cross-sectional illustration of the completion of the secondary radial expansion of the other expandable tubular member of <figref idref="DRAWINGS">FIG. 1</figref><i>k </i>to form a mono-diameter wellbore casing.

0063<figref idref="DRAWINGS">FIG. 2</figref><i>a </i>is a cross sectional illustration of a wellbore including a preexisting wellbore casing.

0064<figref idref="DRAWINGS">FIG. 2</figref><i>b </i>is a cross-sectional illustration of the placement of an embodiment of an apparatus for radially expanding a tubular member into the wellbore of <figref idref="DRAWINGS">FIG. 2</figref><i>a. </i>

0065<figref idref="DRAWINGS">FIG. 2</figref><i>c </i>is a cross-sectional illustration of the injection of fluidic materials through the apparatus of <figref idref="DRAWINGS">FIG. 2</figref><i>b. </i>

0066<figref idref="DRAWINGS">FIG. 2</figref><i>d </i>is a cross-sectional illustration of the injection of hardenable fluidic sealing materials through the apparatus of <figref idref="DRAWINGS">FIG. 2</figref><i>c. </i>

0067<figref idref="DRAWINGS">FIG. 2</figref><i>e </i>is a cross-sectional illustration of the pressurization of the region below the expansion cone of the apparatus of <figref idref="DRAWINGS">FIG. 2</figref><i>d. </i>

0068<figref idref="DRAWINGS">FIG. 2</figref><i>f </i>is a cross-sectional illustration of the continued pressurization of the region below the expansion cone of the apparatus of <figref idref="DRAWINGS">FIG. 2</figref><i>e. </i>

0069<figref idref="DRAWINGS">FIG. 2</figref><i>g </i>is a cross-sectional illustration of the completion of the radial expansion of the expandable tubular member of the apparatus of <figref idref="DRAWINGS">FIG. 2</figref><i>f. </i>

0070<figref idref="DRAWINGS">FIG. 2</figref><i>h </i>is a cross-sectional illustration of the drilling out of a new section of the wellbore below the apparatus of <figref idref="DRAWINGS">FIG. 2</figref><i>g. </i>

0071<figref idref="DRAWINGS">FIG. 2</figref><i>i </i>is a cross-sectional illustration of the radial expansion of another expandable tubular member that overlaps with the apparatus of <figref idref="DRAWINGS">FIG. 2</figref><i>h. </i>

0072<figref idref="DRAWINGS">FIG. 2</figref><i>j </i>is a cross-sectional illustration of the secondary radial expansion of the other expandable tubular member of the apparatus of <figref idref="DRAWINGS">FIG. 2</figref><i>i. </i>

0073<figref idref="DRAWINGS">FIG. 2</figref><i>k </i>is a cross-sectional illustration of the completion of the secondary radial expansion of the other expandable tubular member of <figref idref="DRAWINGS">FIG. 2</figref><i>j </i>to form a mono-diameter wellbore casing.

0074<figref idref="DRAWINGS">FIG. 3</figref> is a cross-sectional illustration of the apparatus of <figref idref="DRAWINGS">FIG. 2</figref><i>b </i>illustrating the design and construction of the over-expansion insert.

0075<figref idref="DRAWINGS">FIG. 3</figref><i>a </i>is a cross-sectional illustration of an alternative embodiment of the over-expansion insert of <figref idref="DRAWINGS">FIG. 3</figref>.

0076<figref idref="DRAWINGS">FIG. 4</figref> is a cross-sectional illustration of an alternative embodiment of the apparatus of <figref idref="DRAWINGS">FIG. 2</figref><i>b </i>including a resilient hook for retrieving the over-expansion insert.

0077<figref idref="DRAWINGS">FIG. 5</figref><i>a </i>is a cross-sectional illustration of a wellbore including a preexisting wellbore casing.

0078<figref idref="DRAWINGS">FIG. 5</figref><i>b </i>is a cross-sectional illustration of the formation of a new section of wellbore casing in the wellbore of <figref idref="DRAWINGS">FIG. 5</figref><i>a. </i>

0079<figref idref="DRAWINGS">FIG. 5</figref><i>c </i>is a fragmentary cross-sectional illustration of the placement of an inflatable bladder into the new section of the wellbore casing of <figref idref="DRAWINGS">FIG. 5</figref><i>b. </i>

0080<figref idref="DRAWINGS">FIG. 5</figref><i>d </i>is a fragmentary cross-sectional illustration of the inflation of the inflatable bladder of <figref idref="DRAWINGS">FIG. 5</figref><i>c. </i>

0081<figref idref="DRAWINGS">FIG. 5</figref><i>e </i>is a cross-sectional illustration of the new section of wellbore casing of <figref idref="DRAWINGS">FIG. 5</figref><i>d </i>after over-expansion.

0082<figref idref="DRAWINGS">FIG. 5</figref><i>f </i>is a cross-sectional illustration of the new section of wellbore casing of <figref idref="DRAWINGS">FIG. 5</figref><i>e </i>after drilling out a new section of the wellbore.

0083<figref idref="DRAWINGS">FIG. 5</figref><i>g </i>is a cross-sectional illustration of the formation of a mono-diameter wellbore casing that includes the new section of the wellbore casing and an additional section of wellbore casing.

0084<figref idref="DRAWINGS">FIG. 6</figref><i>a </i>is a cross-sectional illustration of a wellbore including a preexisting wellbore casing.

0085<figref idref="DRAWINGS">FIG. 6</figref><i>b </i>is a cross-sectional illustration of the formation of a new section of wellbore casing in the wellbore of <figref idref="DRAWINGS">FIG. 6</figref><i>a. </i>

0086<figref idref="DRAWINGS">FIG. 6</figref><i>c </i>is a fragmentary cross-sectional illustration of the placement of a roller radial expansion device into the new section of the wellbore casing of <figref idref="DRAWINGS">FIG. 6</figref><i>b. </i>

0087<figref idref="DRAWINGS">FIG. 6</figref><i>d </i>is a cross-sectional illustration of the new section of wellbore casing of <figref idref="DRAWINGS">FIG. 6</figref><i>c </i>after over-expansion.

0088<figref idref="DRAWINGS">FIG. 6</figref><i>e </i>is a cross-sectional illustration of the new section of wellbore casing of <figref idref="DRAWINGS">FIG. 6</figref><i>d </i>after drilling out a new section of the wellbore.

0089<figref idref="DRAWINGS">FIG. 6</figref><i>f </i>is a cross-sectional illustration of the formation of a mono-diameter wellbore casing that includes the new section of the wellbore casing and an additional section of wellbore casing.

0090<figref idref="DRAWINGS">FIG. 7</figref><i>a </i>is a cross sectional illustration of a wellbore including a preexisting wellbore casing.

0091<figref idref="DRAWINGS">FIG. 7</figref><i>b </i>is a cross-sectional illustration of the placement of an embodiment of an apparatus for radially expanding a tubular member into the wellbore of <figref idref="DRAWINGS">FIG. 7</figref><i>a. </i>

0092<figref idref="DRAWINGS">FIG. 7</figref><i>c </i>is a cross-sectional illustration of the injection of fluidic materials through the apparatus of <figref idref="DRAWINGS">FIG. 7</figref><i>b. </i>

0093<figref idref="DRAWINGS">FIG. 7</figref><i>d </i>is a cross-sectional illustration of the injection of hardenable fluidic sealing materials through the apparatus of <figref idref="DRAWINGS">FIG. 7</figref><i>c. </i>

0094<figref idref="DRAWINGS">FIG. 7</figref><i>e </i>is a cross-sectional illustration of the pressurization of the region below the expansion cone of the apparatus of <figref idref="DRAWINGS">FIG. 7</figref><i>d. </i>

0095<figref idref="DRAWINGS">FIG. 7</figref><i>f </i>is a cross-sectional illustration of the continued pressurization of the region below the expansion cone of the apparatus of <figref idref="DRAWINGS">FIG. 7</figref><i>e. </i>

0096<figref idref="DRAWINGS">FIG. 7</figref><i>g </i>is a cross-sectional illustration of the completion of the radial expansion of the expandable tubular member of the apparatus of <figref idref="DRAWINGS">FIG. 7</figref><i>f. </i>

0097<figref idref="DRAWINGS">FIG. 7</figref><i>h </i>is a cross-sectional illustration of the drilling out of a new section of the wellbore below the apparatus of <figref idref="DRAWINGS">FIG. 7</figref><i>g. </i>

0098<figref idref="DRAWINGS">FIG. 7</figref><i>i </i>is a cross-sectional illustration of the completion of the radial expansion of another expandable tubular member to form a mono-diameter wellbore casing.

0099<figref idref="DRAWINGS">FIG. 8</figref><i>a </i>is cross-sectional illustration of an wellbore including a preexisting section of wellbore casing having a recessed portion.

0100<figref idref="DRAWINGS">FIG. 8</figref><i>b </i>is a cross-sectional illustration of the placement of an apparatus for radially expanding a tubular member within the wellbore of <figref idref="DRAWINGS">FIG. 8</figref><i>a. </i>

0101<figref idref="DRAWINGS">FIG. 8</figref><i>c </i>is a cross-sectional illustration of the injection of fluidic materials through the apparatus of <figref idref="DRAWINGS">FIG. 8</figref><i>b. </i>

0102<figref idref="DRAWINGS">FIG. 8</figref><i>d </i>is a cross-sectional illustration of the injection of a hardenable fluidic sealing material through the apparatus of <figref idref="DRAWINGS">FIG. 8</figref><i>c. </i>

0103<figref idref="DRAWINGS">FIG. 8</figref><i>e </i>is cross-sectional illustration of the isolation of the region below the expansion cone and within the expansion cone launcher of the apparatus of <figref idref="DRAWINGS">FIG. 8</figref><i>d. </i>

0104<figref idref="DRAWINGS">FIG. 8</figref><i>f </i>is a cross-sectional illustration of the plastic deformation and radial expansion of the upper portion of the expandable tubular member of the apparatus of <figref idref="DRAWINGS">FIG. 8</figref><i>e. </i>

0105<figref idref="DRAWINGS">FIG. 8</figref><i>g </i>is a cross-sectional illustration of the removal of the upper expansion cone from the wellbore of <figref idref="DRAWINGS">FIG. 8</figref><i>f. </i>

0106<figref idref="DRAWINGS">FIG. 8</figref><i>h </i>is a cross-sectional illustration of the continued pressurization of the region below the expansion cone of the apparatus of <figref idref="DRAWINGS">FIG. 8</figref><i>g </i>to thereby plastically deform and radially expand the expansion cone launcher and expandable tubular member.

0107<figref idref="DRAWINGS">FIG. 8</figref><i>i </i>is a cross-sectional illustration of the completion of the initial radial expansion process of the apparatus of <figref idref="DRAWINGS">FIG. 8</figref><i>h. </i>

0108<figref idref="DRAWINGS">FIG. 8</figref><i>j </i>is a cross-sectional illustration of the further radial expansion of the apparatus of <figref idref="DRAWINGS">FIG. 8</figref><i>i </i>in order to form a mono-diameter wellbore casing.

0109<figref idref="DRAWINGS">FIG. 9</figref><i>a </i>is a cross-sectional illustration of a wellbore including upper and lower preexisting wellbore casings that are separated by an axial gap.

0110<figref idref="DRAWINGS">FIG. 9</figref><i>b </i>is a cross-sectional illustration of the coupling of a tubular member to the opposing ends of the wellbore casings of <figref idref="DRAWINGS">FIG. 9</figref><i>a. </i>

0111<figref idref="DRAWINGS">FIG. 9</figref><i>c </i>is a fragmentary cross-sectional illustration of the placement of a radial expansion device into the tubular member of <figref idref="DRAWINGS">FIG. 9</figref><i>b. </i>

0112<figref idref="DRAWINGS">FIG. 9</figref><i>d </i>is a fragmentary cross-sectional illustration of the actuation of the radial expansion device of <figref idref="DRAWINGS">FIG. 9</figref><i>c. </i>

0113<figref idref="DRAWINGS">FIG. 9</figref><i>e </i>is a cross-sectional of a mono-diameter wellbore casing generated by the actuation of the radial expansion device of <figref idref="DRAWINGS">FIG. 9</figref><i>d. </i>

0114<figref idref="DRAWINGS">FIG. 10</figref> is a cross-sectional illustration of a mono-diameter wellbore casing that includes a plurality of layers of radially expanded tubular members along at least a portion of the its length.

0115<figref idref="DRAWINGS">FIG. 11</figref><i>a </i>is a cross-sectional illustration of a wellbore including a casing formed by plastically deforming and radially expanding a first tubular member.

0116<figref idref="DRAWINGS">FIG. 11</figref><i>b </i>is a cross-sectional illustration of a wellbore including another casing coupled to the preexisting casing by plastically deforming and radially expanding a second tubular member.

0117<figref idref="DRAWINGS">FIG. 11</figref><i>c </i>is a cross-sectional illustration of a mono-diameter wellbore casing formed by radially expanding the second tubular member a second time.

DETAILED DESCRIPTION

0118Several embodiments of methods and apparatus for forming a mono-diameter wellbore casing are disclosed. In several alternative embodiments, the methods and apparatus may be used for form or repair mono-diameter wellbore casings, pipelines, or structural supports. Furthermore, while the present illustrative embodiments are described with reference to the formation of mono-diameter wellbore casings, the teachings of the present disclosure have general application to the formation or repair of wellbore casings, pipelines, and structural supports.

0119Referring initially to <figref idref="DRAWINGS">FIG. 1</figref><i>a</i>, a wellbore <b>10</b> includes a preexisting wellbore casing <b>15</b>. The wellbore <b>10</b> may be oriented in any orientation from the vertical to the horizontal. The preexisting wellbore casing <b>15</b> may be coupled to the upper portion of the wellbore <b>10</b> using any number of conventional methods. In a preferred embodiment, the wellbore casing <b>15</b> is coupled to the upper portion of the wellbore <b>10</b> using one or more of the methods and apparatus disclosed in one or more of the following: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, and (20) U.S. provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, the disclosures of which are incorporated herein by reference. More generally, the preexisting wellbore casing <b>15</b> may be coupled to another preexisting wellbore casing and/or may include one or more concentrically positioned tubular members.

0120Referring to <figref idref="DRAWINGS">FIG. 1</figref><i>b</i>, an apparatus <b>100</b> for radially expanding a tubular member may then be positioned within the wellbore <b>10</b>. The apparatus <b>100</b> includes a tubular support member <b>105</b> defining a passage <b>110</b> for conveying fluidic materials. An expansion cone <b>115</b> defining a passage <b>120</b> and having an outer conical surface <b>125</b> for radially expanding tubular members is coupled to an end of the tubular support member <b>105</b>. An annular conical over-expansion sleeve <b>130</b> mates with and is removably coupled to the outer conical surface <b>125</b> of the expansion cone <b>115</b>. In several alternative embodiments, the over-expansion sleeve <b>130</b> is fabricated from frangible materials such as, for example, ceramic materials, in order to facilitate the removal of the over-expansion sleeve during operation of the apparatus <b>100</b>. In this manner, the amount of radial expansion provided by the apparatus may be decreased following the removal of the over-expansion sleeve <b>130</b>.

0121An expansion cone launcher <b>135</b> is movably coupled to and supported by the expansion cone <b>115</b> and the over-expansion sleeve <b>130</b>. The expansion cone launcher <b>135</b> include an upper portion having an upper outer diameter, an intermediate portion that mates with the expansion cone <b>115</b> and the over-expansion sleeve <b>130</b>, an a lower portion having a lower outer diameter. The lower outer diameter is greater than the upper outer diameter. A shoe <b>140</b> defining a valveable passage <b>145</b> is coupled to the lower portion of the expansion cone launcher <b>135</b>. In a preferred embodiment, the valveable passage <b>145</b> may be controllably closed in order to fluidicly isolate a region <b>150</b> below the expansion cone <b>115</b> and bounded by the lower portion of the expansion cone launcher <b>135</b> and the shoe <b>140</b> from the region outside of the apparatus <b>100</b>.

0122An expandable tubular member <b>155</b> is coupled to the upper portion of the expansion cone launcher <b>135</b>. One or more sealing members <b>160</b><i>a </i>and <b>160</b><i>b </i>are coupled to the exterior of the upper portion of the expandable tubular member <b>155</b>. In several alternative embodiments, the sealing members <b>160</b><i>a </i>and <b>160</b><i>b </i>may include elastomeric elements and/or metallic elements and/or composite elements. In several alternative embodiments, one or more anchoring elements may substituted for, or used in addition to, the sealing members <b>160</b><i>a </i>and <b>160</b><i>b. </i>

0123In a preferred embodiment, the support member <b>105</b>, the expansion cone <b>115</b>, the expansion cone launcher <b>135</b>, the shoe <b>140</b>, and the expandable tubular member <b>155</b> are provided substantially as disclosed in one or more of the following: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, and (20) U.S. provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, the disclosures of which are incorporated herein by reference.

0124As illustrated in <figref idref="DRAWINGS">FIG. 1</figref><i>b</i>, in a preferred embodiment, during placement of the apparatus <b>100</b> within the wellbore <b>10</b>, fluidic materials <b>165</b> within the wellbore <b>10</b> are conveyed through the apparatus <b>100</b> through the passages <b>110</b>, <b>120</b> and <b>145</b> to a location above the apparatus <b>100</b>. In this manner, surge pressures during placement of the apparatus <b>100</b> within the wellbore <b>10</b> are reduced. In a preferred embodiment, the apparatus <b>100</b> is initially positioned within the wellbore <b>10</b> such that the top portion of the tubular member <b>155</b> overlaps with the preexisting casing <b>15</b>. In this manner, the upper portion of the expandable tubular member <b>155</b> may be radially expanded into contact with and coupled to the preexisting casing <b>15</b>. As will be recognized by persons having ordinary skill in the art, the precise initial position of the expandable tubular member <b>155</b> will vary as a function of the amount of radial expansion, the amount of axial shrinkage during radial expansion, and the material properties of the expandable tubular member.

0125As illustrated in <figref idref="DRAWINGS">FIG. 1</figref><i>c</i>, a fluidic material <b>170</b> may then be injected through the apparatus <b>100</b> through the passages <b>110</b>, <b>120</b>, and <b>145</b> in order to test the proper operation of these passages.

0126As illustrated in <figref idref="DRAWINGS">FIG. 1</figref><i>d</i>, a hardenable fluidic sealing material <b>175</b> may then be injected through the apparatus <b>100</b> through the passages <b>110</b>, <b>120</b> and <b>145</b> into the annulus between the apparatus and the wellbore <b>10</b>. In this manner, an annular barrier to fluid migration into and out of the wellbore <b>10</b> may be formed around the radially expanded expansion cone launcher <b>135</b> and expandable tubular member <b>155</b>. The hardenable fluidic sealing material may include, for example, a cement mixture. In several alternative embodiments, the injection of the hardenable fluidic sealing material <b>175</b> may be omitted. In several alternative embodiments, the hardenable fluidic sealing material <b>175</b> is compressible, before, during and/or after, the curing process.

0127As illustrated in <figref idref="DRAWINGS">FIG. 1</figref><i>e</i>, a non-hardenable fluidic material <b>180</b> may then be injected into the apparatus through the passages <b>110</b> and <b>120</b>. A ball plug <b>185</b>, or other similar device, may then be injected with the fluidic material <b>180</b> to thereby seal off the passage <b>145</b>. In this manner, the region <b>150</b> may be pressurized by the continued injection of the fluidic material <b>180</b> into the apparatus <b>100</b>.

0128As illustrated in <figref idref="DRAWINGS">FIG. 1</figref><i>f</i>, the continued injection of the fluidic material <b>180</b> into the apparatus <b>100</b> causes the expansion cone launcher <b>135</b> and expandable tubular member <b>155</b> to be plastically deformed and radially expanded off of the over-expansion sleeve <b>130</b>. In this manner, the expansion cone <b>115</b> and over-expansion sleeve <b>130</b> are displaced relative to the expansion cone launcher <b>135</b> and expandable tubular member <b>155</b> in the axial direction.

0129After a predetermined time period and/or after a predetermined axial displacement of the expansion cone <b>115</b> relative to the expansion cone launcher <b>135</b> and expandable tubular member <b>155</b>, the over-expansion sleeve <b>130</b> may be removed from the outer conical surface <b>125</b> of the expansion cone <b>115</b> by the application of a predetermined upward shock load to the support member <b>105</b>. In a preferred embodiment, the shock load causes the frangible over-expansion sleeve <b>130</b> to fracture into small pieces that are then forced off of the outer conical surface <b>125</b> of the expansion cone <b>115</b> by the continued pressurization of the region <b>150</b>. In a preferred embodiment, the pieces of the over-expansion sleeve <b>130</b> are pulverized into grains of material by the continued pressurization of the region <b>150</b>.

0130Referring to <figref idref="DRAWINGS">FIG. 1</figref><i>g</i>, following the removal of the frangible over-expansion sleeve <b>130</b>, the continued pressurization of the region <b>150</b> causes the expandable tubular member <b>155</b> to be plastically deformed and radially expanded and extruded off of the outer conical surface <b>125</b> of the expansion cone <b>115</b>. Note that the amount of radial expansion provided by the outer conical surface <b>125</b> of expansion cone <b>115</b> is less than the amount of radial expansion provided by the combination of the over-expansion sleeve <b>130</b> and the expansion cone <b>115</b>. In this manner, as illustrated in <figref idref="DRAWINGS">FIG. 1</figref><i>h</i>, a recess <b>185</b> is formed in the radially expanded tubular member <b>155</b>.

0131After completing the plastic deformation and radial expansion of the tubular member <b>155</b>, the hardenable fluidic sealing material is allowed to cure to thereby form an annular body <b>190</b> that provides a barrier to fluid flow into or out of the wellbore <b>10</b>.

0132Referring to <figref idref="DRAWINGS">FIG. 1</figref><i>i</i>, the shoe <b>140</b> may then removed by drilling out the shoe using a conventional drilling device. A new section of the wellbore <b>10</b> may also be drilled out in order to permit additional expandable tubular members to be coupled to the bottom portion of the plastically deformed and radially expanded tubular member <b>155</b>.

0133Referring to <figref idref="DRAWINGS">FIG. 1</figref><i>j</i>, a tubular member <b>200</b> may then be plastically deformed and radially expanded using any number of conventional methods of radially expanding a tubular member. In a preferred embodiment, the upper portion of the radially expanded tubular member <b>200</b> overlaps with and mates with the recessed portion <b>185</b> of the tubular member <b>155</b>. In a preferred embodiment, one or more sealing members <b>205</b> are coupled to the exterior surface of the upper portion of the tubular member <b>200</b>. In a preferred embodiment, the sealing members <b>205</b> seal the interface between the upper portion of the tubular member <b>200</b> and the recessed portion <b>185</b> of the tubular member <b>155</b>. In several alternative embodiments, the sealing members <b>205</b> may include elastomeric elements and/or metallic elements and/or composite elements. In several alternative embodiments, one or more anchoring elements may substituted for, or used in addition to, the sealing members <b>205</b>. In a preferred embodiment, an annular body <b>210</b> of a hardenable fluidic sealing material is also formed around the tubular member <b>200</b> using one or more conventional methods.

0134In a preferred embodiment, the tubular member <b>200</b> is plastically deformed and radially expanded, and the annular body <b>210</b> is formed using one or more of the apparatus and methods disclosed in the following: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, and (20) U.S. provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, the disclosures of which are incorporated herein by reference.

0135In an alternative embodiment, the annular body <b>210</b> may be omitted. In several alternative embodiments, the annular body <b>210</b> may be radially compressed before, during and/or after curing.

0136Referring to <figref idref="DRAWINGS">FIG. 1</figref><i>k</i>, an expansion cone <b>215</b> may then be driven in a downward direction by fluid pressure and/or by a support member <b>220</b> to plastically deform and radially expand the tubular member <b>200</b> such that the interior diameter of the tubular members <b>155</b> and <b>200</b> are substantially equal. In this manner, as illustrated in <figref idref="DRAWINGS">FIG. 1</figref><i>l</i>, a mono-diameter wellbore casing may be formed. In a preferred embodiment, during the displacement of the expansion cone <b>215</b> in the downward direction, fluidic materials displaced by the expansion cone are conveyed out of the wellbore by an internal passage <b>220</b><i>a </i>defined within the support member <b>220</b>.

0137Referring to <figref idref="DRAWINGS">FIGS. 2</figref><i>a </i>and <b>2</b><i>b</i>, in an alternative embodiment, an apparatus <b>300</b> for radially expanding a tubular member may then be positioned within the wellbore <b>10</b>. The apparatus <b>300</b> includes a tubular support member <b>305</b> defining a passage <b>310</b> for conveying fluidic materials. An expansion cone <b>315</b> defining a passage <b>320</b> and having an outer conical surface <b>325</b> for radially expanding tubular members is coupled to an end of the tubular support member <b>305</b>. An annular conical over-expansion insert <b>330</b> mates with and is removably coupled to the outer conical surface <b>325</b> of the expansion cone <b>315</b>.

0138An expansion cone launcher <b>335</b> is movably coupled to and supported by the expansion cone <b>315</b> and the over-expansion insert <b>330</b>. The expansion cone launcher <b>335</b> includes an upper portion having an upper outer diameter, an intermediate portion that mates with the expansion cone <b>315</b> and the over-expansion insert <b>330</b>, an a lower portion having a lower outer diameter. The lower outer diameter is greater than the upper outer diameter. A shoe <b>340</b> defining a valveable passage <b>345</b> is coupled to the lower portion of the expansion cone launcher <b>335</b>. In a preferred embodiment, the valveable passage <b>345</b> may be controllably closed in order to fluidicly isolate a region <b>350</b> below the expansion cone <b>315</b> and bounded by the lower portion of the expansion cone launcher <b>335</b> and the shoe <b>340</b> from the region outside of the apparatus <b>300</b>.

0139In a preferred embodiment, as illustrated in <figref idref="DRAWINGS">FIG. 3</figref>, the over-expansion insert <b>330</b> includes a plurality of spaced-apart arcuate inserts <b>330</b><i>a</i>, <b>330</b><i>b</i>, <b>330</b><i>c </i>and <b>330</b><i>d </i>that are positioned between the outer conical surface <b>325</b> of the expansion cone <b>315</b> and the inner surface of the intermediate portion of the expansion cone launcher <b>335</b>. In this manner, the relative axial displacement of the expansion cone <b>315</b> and the expansion cone launcher <b>335</b> will cause the expansion cone to over-expand the intermediate portion of the expansion cone launcher. In this manner, a recess may be formed in the radially expanded expansion cone launcher <b>335</b>. In several alternative embodiments, the inserts <b>330</b><i>a</i>, <b>330</b><i>b</i>, <b>330</b><i>c</i>, and <b>330</b><i>d </i>fall out of the recess and/or are removed from the recess using a conventional retrieval tool upon the completion of the radial expansion process.

0140In an alternative embodiment, as illustrated in <figref idref="DRAWINGS">FIG. 3</figref><i>a</i>, the over expansion insert <b>330</b> further includes intermediate resilient members <b>331</b><i>a</i>, <b>331</b><i>b</i>, <b>331</b><i>c</i>, and <b>331</b><i>d </i>for resiliently coupling the inserts <b>330</b><i>a</i>, <b>330</b><i>b</i>, <b>330</b><i>c</i>, and <b>330</b><i>d</i>. In this manner, upon the completion of the radial expansion process, the resilient force exerted by the resilient members <b>331</b> causes the over-expansion insert to collapse in the radial direction and thereby fall out of the recess.

0141An expandable tubular member <b>355</b> is coupled to the upper portion of the expansion cone launcher <b>335</b>. One or more sealing members <b>360</b><i>a </i>and <b>360</b><i>b </i>are coupled to the exterior of the upper portion of the expandable tubular member <b>355</b>. In several alternative embodiments, the sealing members <b>360</b><i>a </i>and <b>360</b><i>b </i>may include elastomeric elements and/or metallic elements and/or composite elements. In several alternative embodiments, one or more anchoring elements may substituted for, or used in addition to, the sealing members <b>360</b><i>a </i>and <b>360</b><i>b. </i>

0142In a preferred embodiment, the support member <b>305</b>, the expansion cone <b>315</b>, the expansion cone launcher <b>335</b>, the shoe <b>340</b>, and the expandable tubular member <b>355</b> are provided substantially as disclosed in one or more of the following: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, and (20) U.S. provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, the disclosures of which are incorporated herein by reference.

0143As illustrated in <figref idref="DRAWINGS">FIG. 2</figref><i>b</i>, in a preferred embodiment, during placement of the apparatus <b>300</b> within the wellbore <b>10</b>, fluidic materials <b>365</b> within the wellbore <b>10</b> are conveyed through the apparatus <b>300</b> through the passages <b>310</b>, <b>320</b> and <b>345</b> to a location above the apparatus <b>300</b>. In this manner, surge pressures during placement of the apparatus <b>300</b> within the wellbore <b>10</b> are reduced. In a preferred embodiment, the apparatus <b>300</b> is initially positioned within the wellbore <b>10</b> such that the top portion of the tubular member <b>355</b> overlaps with the preexisting casing <b>15</b>. In this manner, the upper portion of the expandable tubular member <b>355</b> may be radially expanded into contact with and coupled to the preexisting casing <b>15</b>. As will be recognized by persons having ordinary skill in the art, the precise initial position of the expandable tubular member <b>355</b> will vary as a function of the amount of radial expansion, the amount of axial shrinkage during radial expansion, and the material properties of the expandable tubular member.

0144As illustrated in <figref idref="DRAWINGS">FIG. 2</figref><i>c</i>, a fluidic material <b>370</b> may then be injected through the apparatus <b>300</b> through the passages <b>310</b>, <b>320</b>, and <b>345</b> in order to test the proper operation of these passages.

0145As illustrated in <figref idref="DRAWINGS">FIG. 2</figref><i>d</i>, a hardenable fluidic sealing material <b>375</b> may then be injected through the apparatus <b>300</b> through the passages <b>310</b>, <b>320</b> and <b>345</b> into the annulus between the apparatus and the wellbore <b>10</b>. In this manner, an annular barrier to fluid migration into and out of the wellbore <b>10</b> may be formed around the radially expanded expansion cone launcher <b>335</b> and expandable tubular member <b>355</b>. The hardenable fluidic sealing material may include, for example, a cement mixture. In several alternative embodiments, the injection of the hardenable fluidic sealing material <b>375</b> may be omitted. In several alternative embodiments, the hardenable fluidic sealing material <b>375</b> is compressible, before, during and/or after, the curing process.

0146As illustrated in <figref idref="DRAWINGS">FIG. 2</figref><i>e</i>, a non-hardenable fluidic material <b>380</b> may then be injected into the apparatus through the passages <b>310</b> and <b>320</b>. A ball plug <b>385</b>, or other similar device, may then be injected with the fluidic material <b>380</b> to thereby seal off the passage <b>345</b>. In this manner, the region <b>350</b> may be pressurized by the continued injection of the fluidic material <b>380</b> into the apparatus <b>300</b>.

0147As illustrated in <figref idref="DRAWINGS">FIG. 2</figref><i>f</i>, the continued injection of the fluidic material <b>380</b> into the apparatus <b>300</b> causes the expansion cone launcher <b>335</b> to be plastically deformed and radially expanded off of the over-expansion insert <b>330</b>. In this manner, the expansion cone <b>315</b> is displaced relative to the expansion cone launcher <b>335</b> and expandable tubular member <b>355</b> in the axial direction.

0148Once the radial expansion process has progressed beyond the over-expansion insert <b>330</b>, the radial expansion of the expansion cone launcher <b>335</b> and expandable tubular member <b>355</b> is provided solely by the outer conical surface <b>325</b> of the expansion cone <b>315</b>. Note that the amount of radial expansion provided by the outer conical surface <b>325</b> of expansion cone <b>315</b> is less than the amount of radial expansion provided by the combination of the over-expansion insert <b>330</b> and the expansion cone <b>315</b>. In this manner, as illustrated in <figref idref="DRAWINGS">FIG. 2</figref><i>g</i>, a recess <b>390</b> is formed in the radially expanded tubular member <b>355</b>.

0149In several alternative embodiments, the over-expansion insert <b>330</b> is removed from the recess <b>390</b> by falling out and/or removal using a conventional retrieval tool. In an alternative embodiment, the resilient force provided by the resilient members <b>331</b><i>a</i>, <b>331</b><i>b</i>, <b>331</b><i>c</i>, and <b>331</b><i>d </i>cause the insert <b>330</b> to collapse in the radial direction and thereby fall out of the recess <b>390</b>. In an alternative embodiment, as illustrated in <figref idref="DRAWINGS">FIG. 4</figref>, one or more resilient hooks <b>395</b><i>a </i>and <b>395</b><i>b </i>are coupled to the bottom of the expansion cone <b>315</b> for retrieving the over-expansion insert <b>330</b> during or after the completion of the radial expansion process.

0150After completing the plastic deformation and radial expansion of the tubular member <b>355</b>, the hardenable fluidic sealing material is allowed to cure to thereby form an annular body <b>400</b> that provides a barrier to fluid flow into or out of the wellbore <b>10</b>.

0151Referring to <figref idref="DRAWINGS">FIG. 2</figref><i>h</i>, the shoe <b>340</b> may then removed by drilling out the shoe using a conventional drilling device. A new section of the wellbore <b>10</b> may also be drilled out in order to permit additional expandable tubular members to be coupled to the bottom portion of the plastically deformed and radially expanded tubular member <b>355</b>.

0152Referring to <figref idref="DRAWINGS">FIG. 2</figref><i>i</i>, a tubular member <b>405</b> may then be plastically deformed and radially expanded using any number of conventional methods of radially expanding a tubular member. In a preferred embodiment, the upper portion of the radially expanded tubular member <b>405</b> overlaps with and mates with the recessed portion <b>390</b> of the tubular member <b>355</b>. In a preferred embodiment, one or more sealing members <b>410</b> are coupled to the exterior surface of the upper portion of the tubular member <b>405</b>. In a preferred embodiment, the sealing members <b>410</b> seal the interface between the upper portion of the tubular member <b>405</b> and the recessed portion <b>390</b> of the tubular member <b>355</b>. In several alternative embodiments, the sealing members <b>410</b> may include elastomeric elements and/or metallic elements and/or composite elements. In several alternative embodiments, one or more anchoring elements may substituted for, or used in addition to, the sealing members <b>410</b>. In a preferred embodiment, an annular body <b>415</b> of a hardenable fluidic sealing material is also formed around the tubular member <b>405</b> using one or more conventional methods.

0153In a preferred embodiment, the tubular member <b>405</b> is plastically deformed and radially expanded, and the annular body <b>415</b> is formed using one or more of the apparatus and methods disclosed in the following: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, and (20) U.S. provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, the disclosures of which are incorporated herein by reference.

0154In an alternative embodiment, the annular body <b>415</b> may be omitted. In several alternative embodiments, the annular body <b>415</b> may be radially compressed before, during and/or after curing.

0155Referring to <figref idref="DRAWINGS">FIG. 2</figref><i>j</i>, an expansion cone <b>420</b> may then be driven in a downward direction by fluid pressure and/or by a support member <b>425</b> to plastically deform and radially expand the tubular member <b>405</b> such that the interior diameter of the tubular members <b>355</b> and <b>405</b> are substantially equal. In this manner, as illustrated in <figref idref="DRAWINGS">FIG. 2</figref><i>k</i>, a mono-diameter wellbore casing may be formed. In a preferred embodiment, during the displacement of the expansion cone <b>420</b> in the downward direction, fluidic materials displaced by the expansion cone are conveyed out of the wellbore by an internal passage <b>425</b><i>a </i>defined within the support member <b>425</b>.

0156Referring to <figref idref="DRAWINGS">FIGS. 5</figref><i>a</i>–<b>5</b><i>b</i>, in an alternative embodiment, a tubular member <b>500</b> having a shoe <b>505</b> may be plastically deformed and radially expanded and thereby coupled to the preexisting section of wellbore casing <b>15</b> using any number of conventional methods. An annular body of a fluidic sealing material <b>510</b> may also be formed around the tubular member <b>500</b> using any number of conventional methods. In a preferred embodiment, the tubular member <b>500</b> is plastically deformed and radially expanded and the annular body <b>510</b> is formed using one or more of the methods and apparatus disclosed in one or more of the following: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, and (20) U.S. provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, the disclosures of which are incorporated herein by reference.

0157In several alternative embodiments, the annular body <b>510</b> may be omitted or may be compressible before, during, or after curing.

0158Referring to <figref idref="DRAWINGS">FIGS. 5</figref><i>c </i>and <b>5</b><i>d</i>, a conventional inflatable bladder <b>515</b> may then be positioned within the tubular member <b>500</b> and inflated to a sufficient operating pressure to plastically deform and radially expand a portion of the tubular member to thereby form a recess <b>520</b> in the tubular member.

0159Referring to <figref idref="DRAWINGS">FIGS. 5</figref><i>e </i>and <b>5</b><i>f</i>, the inflatable bladder <b>515</b> may then be removed and the shoe <b>505</b> drilled out using a conventional drilling device.

0160Referring to <figref idref="DRAWINGS">FIG. 5</figref><i>g</i>, an additional tubular member <b>525</b> may then be plastically deformed and radially expanded in a conventional manner and/or by using one or more of the methods and apparatus described above in order to form a mono-diameter wellbore casing. Before, during or after the radial expansion of the tubular member <b>525</b>, an annular body <b>530</b> of a fluidic sealing material may be formed around the tubular member in a conventional manner and/or by using one or more of the methods and apparatus described above.

0161In several alternative embodiments, the inflatable bladder <b>515</b> may be coupled to the bottom of an expansion cone in order to permit the over-expansion process to be performed during the radial expansion process implemented using the expansion cone.

0162Referring to <figref idref="DRAWINGS">FIGS. 6</figref><i>a</i>–<b>6</b><i>b</i>, in an alternative embodiment, a tubular member <b>600</b> having a shoe <b>605</b> may be plastically deformed and radially expanded and thereby coupled to the preexisting section of wellbore casing <b>15</b> using any number of conventional methods. An annular body of a fluidic sealing material <b>610</b> may also be formed around the tubular member <b>600</b> using any number of conventional methods. In a preferred embodiment, the tubular member <b>600</b> is plastically deformed and radially expanded and the annular body <b>610</b> is formed using one or more of the methods and apparatus disclosed in one or more of the following: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, and (20) U.S. provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, the disclosures of which are incorporated herein by reference.

0163In several alternative embodiments, the annular body <b>610</b> may be omitted or may be compressible before, during, or after curing.

0164Referring to <figref idref="DRAWINGS">FIGS. 6</figref><i>c </i>and <b>6</b><i>d</i>, a conventional roller expansion device <b>615</b> may then be positioned within the tubular member <b>600</b> and operated in a conventional manner apply a radial force to the interior surface of the tubular member <b>600</b> to plastically deform and radially expand a portion of the tubular member to thereby form a recess <b>620</b> in the tubular member. As will be recognized by persons having ordinary skill in the art, a roller expansion device typically utilizes one or more rollers that, through rotation of the device, apply a radial force to the interior surfaces of a tubular member. In several alternative embodiments, the roller expansion device <b>615</b> may include eccentric rollers such as, for example, as disclosed in U.S. Pat. Nos. 5,014,779 and 5,083,608, the disclosures of which are incorporated herein by reference.

0165Referring to <figref idref="DRAWINGS">FIGS. 6</figref><i>d </i>and <b>6</b><i>e</i>, the roller expansion device <b>615</b> may then be removed and the shoe <b>605</b> drilled out using a conventional drilling device.

0166Referring to <figref idref="DRAWINGS">FIG. 6</figref><i>f</i>, an additional tubular member <b>625</b> may then be plastically deformed and radially expanded in a conventional manner and/or by using one or more of the methods and apparatus described above in order to form a mono-diameter wellbore casing. Before, during or after the radial expansion of the tubular member <b>625</b>, an annular body <b>630</b> of a fluidic sealing material may be formed around the tubular member in a conventional manner and/or by using one or more of the methods and apparatus described above.

0167In several alternative embodiments, the roller expansion device <b>615</b> may be coupled to the bottom of an expansion cone in order to permit the over-expansion process to be performed during the radial expansion process implemented using the expansion cone.

0168Referring initially to <figref idref="DRAWINGS">FIG. 7</figref><i>a</i>, a wellbore <b>10</b> includes a preexisting wellbore casing <b>15</b>. The wellbore <b>10</b> may be oriented in any orientation from the vertical to the horizontal. The preexisting wellbore casing <b>15</b> may be coupled to the upper portion of the wellbore <b>10</b> using any number of conventional methods. In a preferred embodiment, the wellbore casing <b>15</b> is coupled to the upper portion of the wellbore <b>10</b> using one or more of the methods and apparatus disclosed in one or more of the following: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, and (20) U.S. provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, the disclosures of which are incorporated herein by reference. More generally, the preexisting wellbore casing <b>15</b> may be coupled to another preexisting wellbore casing and/or may include one or more concentrically positioned tubular members.

0169Referring to <figref idref="DRAWINGS">FIG. 7</figref><i>b</i>, an apparatus <b>700</b> for radially expanding a tubular member may then be positioned within the wellbore <b>10</b>. The apparatus <b>700</b> includes a tubular support member <b>705</b> defining a passage <b>710</b> for conveying fluidic materials. An expansion cone <b>715</b> defining a passage <b>720</b> and having an outer conical surface <b>725</b> for radially expanding tubular members is coupled to an end of the tubular support member <b>705</b>.

0170An expansion cone launcher <b>735</b> is movably coupled to and supported by the expansion cone <b>715</b>. The expansion cone launcher <b>735</b> includes an upper portion <b>735</b><i>a </i>having an upper outer diameter, an intermediate portion <b>735</b><i>b </i>that mates with the expansion cone <b>715</b>, and a lower portion <b>735</b><i>c </i>having a lower outer diameter. The lower outer diameter is greater than the upper outer diameter. The expansion cone launcher <b>735</b> further includes a recessed portion <b>735</b><i>d </i>having an outer diameter that is less than the lower outer diameter.

0171A shoe <b>740</b> defining a valveable passage <b>745</b> is coupled to the lower portion of the expansion cone launcher <b>735</b>. In a preferred embodiment, the valveable passage <b>745</b> may be controllably closed in order to fluidicly isolate a region <b>750</b> below the expansion cone <b>715</b> and bounded by the lower portion <b>735</b><i>c </i>of the expansion cone launcher <b>735</b> and the shoe <b>740</b> from the region outside of the apparatus <b>700</b>.

0172An expandable tubular member <b>755</b> is coupled to the upper portion <b>735</b><i>a </i>of the expansion cone launcher <b>735</b>. One or more sealing members <b>760</b><i>a </i>and <b>760</b><i>b </i>may be coupled to the exterior of the upper portion of the expandable tubular member <b>755</b>. In several alternative embodiments, the sealing members <b>760</b><i>a </i>and <b>760</b><i>b </i>may include elastomeric elements and/or metallic elements and/or composite elements. In several alternative embodiments, one or more anchoring elements may substituted for, or used in addition to, the sealing members <b>760</b><i>a </i>and <b>760</b><i>b. </i>

0173In a preferred embodiment, the support member <b>705</b>, the expansion cone <b>715</b>, the expansion cone launcher <b>735</b>, the shoe <b>740</b>, and the expandable tubular member <b>755</b> are provided substantially as disclosed in one or more of the following: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, and (20) U.S. provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, the disclosures of which are incorporated herein by reference.

0174As illustrated in <figref idref="DRAWINGS">FIG. 7</figref><i>b</i>, in a preferred embodiment, during placement of the apparatus <b>700</b> within the wellbore <b>10</b>, fluidic materials <b>765</b> within the wellbore <b>10</b> are conveyed through the apparatus <b>700</b> through the passages <b>710</b>, <b>720</b> and <b>745</b> to a location above the apparatus <b>700</b>. In this manner, surge pressures during placement of the apparatus <b>700</b> within the wellbore <b>10</b> are reduced. In a preferred embodiment, the apparatus <b>700</b> is initially positioned within the wellbore <b>10</b> such that the top portion of the tubular member <b>755</b> overlaps with the preexisting casing <b>15</b>. In this manner, the upper portion of the expandable tubular member <b>755</b> may be radially expanded into contact with and coupled to the preexisting casing <b>15</b>. As will be recognized by persons having ordinary skill in the art, the precise initial position of the expandable tubular member <b>755</b> will vary as a function of the amount of radial expansion, the amount of axial shrinkage during radial expansion, and the material properties of the expandable tubular member.

0175As illustrated in <figref idref="DRAWINGS">FIG. 7</figref><i>c</i>, a fluidic material <b>770</b> may then be injected through the apparatus <b>700</b> through the passages <b>710</b>, <b>720</b>, and <b>745</b> in order to test the proper operation of these passages.

0176As illustrated in <figref idref="DRAWINGS">FIG. 7</figref><i>d</i>, a hardenable fluidic sealing material <b>775</b> may then be injected through the apparatus <b>700</b> through the passages <b>710</b>, <b>720</b> and <b>745</b> into the annulus between the apparatus and the wellbore <b>10</b>. In this manner, an annular barrier to fluid migration into and out of the wellbore <b>10</b> may be formed around the radially expanded expansion cone launcher <b>735</b> and expandable tubular member <b>755</b>. The hardenable fluidic sealing material may include, for example, a cement mixture. In several alternative embodiments, the injection of the hardenable fluidic sealing material <b>775</b> may be omitted. In several alternative embodiments, the hardenable fluidic sealing material <b>775</b> is compressible, before, during and/or after, the curing process.

0177As illustrated in <figref idref="DRAWINGS">FIG. 7</figref><i>e</i>, a non-hardenable fluidic material <b>780</b> may then be injected into the apparatus through the passages <b>710</b> and <b>720</b>. A ball plug <b>785</b>, or other similar device, may then be injected with the fluidic material <b>780</b> to thereby seal off the passage <b>745</b>. In this manner, the region <b>750</b> may be pressurized by the continued injection of the fluidic material <b>780</b> into the apparatus <b>700</b>.

0178As illustrated in <figref idref="DRAWINGS">FIGS. 7</figref><i>f </i>and <b>7</b><i>g</i>, the continued injection of the fluidic material <b>780</b> into the apparatus <b>700</b> causes the expansion cone launcher <b>735</b> and expandable tubular member <b>755</b> to be plastically deformed and radially expanded off of the expansion cone <b>715</b>. The resulting structure includes a lip <b>790</b>.

0179After completing the plastic deformation and radial expansion of the tubular member <b>755</b>, the hardenable fluidic sealing material is allowed to cure to thereby form an annular body <b>795</b> that provides a barrier to fluid flow into or out of the wellbore <b>10</b>.

0180Referring to <figref idref="DRAWINGS">FIG. 7</figref><i>h</i>, the shoe <b>740</b> may then removed by drilling out the shoe using a conventional drilling device. A new section of the wellbore <b>10</b> may also be drilled out in order to permit additional expandable tubular members to be coupled to the bottom portion of the plastically deformed and radially expanded tubular member <b>755</b>.

0181Referring to <figref idref="DRAWINGS">FIG. 7</figref><i>i</i>, an additional tubular member <b>800</b> may then be plastically deformed and radially expanded in a conventional manner and/or by using one or more of the methods and apparatus described above in order to form a mono-diameter wellbore casing. Before, during or after the radial expansion of the tubular member <b>800</b>, an annular body <b>805</b> of a fluidic sealing material may be formed around the tubular member in a conventional manner and/or by using one or more of the methods and apparatus described above. In a preferred embodiment, the lip <b>790</b> facilitates the coupling of the tubular member <b>800</b> to the tubular member <b>755</b> by providing a region on which the tubular member <b>800</b> may be easily coupled onto.

0182Referring to <figref idref="DRAWINGS">FIG. 8</figref><i>a</i>, in an alternative embodiment, a wellbore <b>10</b> includes a preexisting section of wellbore casing <b>15</b> and <b>900</b>. The wellbore casing <b>900</b> includes sealing members <b>905</b><i>a </i>and <b>905</b><i>b </i>and a recess <b>910</b>. An annular body <b>915</b> of a fluidic sealing material may also be provided around the casing <b>900</b>. The casing <b>900</b> and annular body <b>915</b> may be provided using any number of conventional methods, the methods described above, and/or using one or more of the methods disclosed in the following: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, and (20) U.S. provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, the disclosures of which are incorporated herein by reference.

0183Referring to <figref idref="DRAWINGS">FIG. 8</figref><i>b</i>, an apparatus <b>1000</b> for radially expanding a tubular member is then positioned within the wellbore <b>10</b> that includes a tubular support member <b>1005</b> that defines a passage <b>1010</b> for conveying fluidic materials. A hydraulic locking device <b>1015</b> that defines a passage <b>1020</b> for conveying fluidic materials that is fluidicly coupled to the passage <b>1010</b>. The locking device <b>1015</b> further includes inlet passages, <b>1020</b><i>a </i>and <b>1020</b><i>b</i>, chambers, <b>1025</b><i>a </i>and <b>1025</b><i>b</i>, and locking members, <b>1030</b><i>a </i>and <b>1030</b><i>b</i>. During operation, the injection of fluidic materials into the actuating chambers, <b>1025</b><i>a </i>and <b>1025</b><i>b</i>, causes the locking members, <b>1030</b><i>a </i>and <b>1030</b><i>b</i>, to be displaced outwardly in the radial direction. In this manner, the locking device <b>1015</b> may be controllably coupled to a tubular member to thereby maintain the tubular member in a substantially stationary position. As will be recognized by persons having ordinary skill in the art, the operating pressures and physical shape of the inlet passages <b>1020</b>, actuating chambers <b>1025</b>, and locking members <b>1030</b> will determine the maximum amount of holding force provided by the locking device <b>1015</b>. In several alternative embodiments, fluidic materials may be injected into the locking device <b>1015</b> using a dedicated fluid passage in order to provide precise control of the locking device. In several alternative embodiments, the locking device <b>1015</b> may be omitted and the tubular support member <b>1005</b> coupled directly to the tubular support member <b>1035</b>.

0184One end of a tubular support member <b>1035</b> that defines a passage <b>1040</b> is coupled to the locking device <b>1015</b>. The passage <b>1040</b> is fluidicly coupled to the passage <b>1020</b>. An expansion cone <b>1045</b> that defines a passage <b>1050</b> and includes an outer conical surface <b>1055</b> is coupled to another end of the tubular support member <b>1035</b>. An expansion cone launcher <b>1060</b> is movably coupled to and supported by the expansion cone <b>1045</b>. The expansion cone launcher <b>1060</b> includes an upper portion <b>1060</b><i>a </i>having an upper outside diameter, an intermediate portion <b>1060</b><i>b </i>that mates with the expansion cone <b>1045</b>, and a lower portion <b>1060</b><i>c </i>having a lower outside diameter. The lower outside diameter is greater than the upper outside diameter.

0185A shoe <b>1065</b> that defines a valveable passage <b>1070</b> is coupled to the lower portion <b>1060</b><i>c </i>of the expansion cone launcher <b>1060</b>. In this manner, a region <b>1075</b> below the expansion cone <b>1045</b> and bounded by the expansion cone launcher <b>1060</b> and the shoe <b>1065</b> may be pressurized and fluidicly isolated from the annular region between the apparatus <b>1000</b> and the wellbore <b>10</b>.

0186An expandable tubular member <b>1080</b> is coupled to the upper portion of the expansion cone launcher <b>1060</b>. In several alternative embodiments, one or more sealing members are coupled to the exterior of the upper portion of the expandable tubular member <b>1080</b>. In several alternative embodiments, the sealing members may include elastomeric elements and/or metallic elements and/or composite elements. In several alternative embodiments, one or more anchoring elements may substituted for, or used in addition to, the sealing members.

0187An expansion cone <b>1085</b> defining a passage <b>1090</b> for receiving the tubular support member <b>1005</b> includes an outer conical surface <b>1095</b>. A tubular support member <b>1100</b> defining a passage <b>1105</b> for receiving the tubular support member <b>1005</b> is coupled to the bottom of the expansion cone <b>1085</b> for supporting and actuating the expansion cone.

0188In a preferred embodiment, the support members <b>1005</b> and <b>1035</b>, the expansion cone <b>1045</b>, the expansion cone launcher <b>1060</b>, the shoe <b>1065</b>, and the expandable tubular member <b>1080</b> are provided substantially as disclosed in one or more of the following: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, and (20) U.S. provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, the disclosures of which are incorporated herein by reference.

0189As illustrated in <figref idref="DRAWINGS">FIG. 8</figref><i>b</i>, in a preferred embodiment, during placement of the apparatus <b>1000</b> within the wellbore <b>10</b>, fluidic materials <b>1110</b> within the wellbore <b>10</b> are conveyed through the apparatus <b>1000</b> through the passages <b>1010</b>, <b>1020</b>, <b>1040</b> and <b>1070</b> to a location above the apparatus <b>1000</b>. In this manner, surge pressures during placement of the apparatus <b>1000</b> within the wellbore <b>10</b> are reduced. In a preferred embodiment, the apparatus <b>1000</b> is initially positioned within the wellbore <b>10</b> such that the top portion of the tubular member <b>1080</b> overlaps with the recess <b>910</b> of the preexisting casing <b>900</b>. In this manner, the upper portion of the expandable tubular member <b>1080</b> may be radially expanded into contact with and coupled to the recess <b>910</b> of the preexisting casing <b>900</b>.

0190As illustrated in <figref idref="DRAWINGS">FIG. 8</figref><i>c</i>, a fluidic material <b>1115</b> may then be injected through the apparatus <b>1000</b> through the passages <b>1010</b>, <b>1020</b>, <b>1040</b>, and <b>1070</b> in order to test the proper operation of these passages.

0191As illustrated in <figref idref="DRAWINGS">FIG. 8</figref><i>d</i>, a hardenable fluidic sealing material <b>1120</b> may then be injected through the apparatus <b>1000</b> through the passages <b>1010</b>, <b>1020</b>, <b>1040</b>, and <b>1070</b> into the annulus between the apparatus and the wellbore <b>10</b>. In this manner, an annular barrier to fluid migration into and out of the wellbore <b>10</b> may be formed around the radially expanded expansion cone launcher <b>1060</b> and expandable tubular member <b>1080</b>. The hardenable fluidic sealing material may include, for example, a cement mixture. In several alternative embodiments, the injection of the hardenable fluidic sealing material <b>1120</b> may be omitted. In several alternative embodiments, the hardenable fluidic sealing material <b>1120</b> is compressible, before, during and/or after, the curing process.

0192As illustrated in <figref idref="DRAWINGS">FIG. 8</figref><i>e</i>, a non-hardenable fluidic material <b>1125</b> may then be injected into the apparatus <b>1000</b> through the passages <b>1010</b>, <b>1020</b> and <b>1040</b>. A ball plug <b>1130</b>, or other similar device, may then be injected with the fluidic material <b>1125</b> to thereby seal off the passage <b>1070</b>. In this manner, the region <b>1075</b> may be pressurized by the continued injection of the fluidic material <b>1125</b> into the apparatus <b>1000</b>. Furthermore, in this manner, the actuating chambers, <b>1025</b><i>a </i>and <b>1025</b><i>b</i>, of the locking device <b>1015</b> may be pressurized. In this manner, the tubular member <b>1080</b> may be held in a substantially stationary position by the locking device <b>1015</b>.

0193As illustrated in <figref idref="DRAWINGS">FIG. 8</figref><i>f</i>, the expansion cone <b>1085</b> may then be actuated in the downward direction by a direct application of axial force using the support member <b>1100</b> and/or through the application of fluid force. The axial displacement of the expansion cone <b>1085</b> may plastically deform and radially expand the upper portion of the expandable tubular member <b>1080</b>. In this manner, the upper portion of the expandable tubular member <b>1080</b> may be precisely coupled to the recess <b>910</b> of the preexisting casing <b>900</b>.

0194During the downward actuation of the expansion cone <b>1085</b>, the locking member <b>1015</b> preferably prevents axial displacement of the tubular member <b>1080</b>. In a preferred embodiment, the locking member <b>1015</b> is positioned proximate the upper portion of the tubular member <b>1080</b> in order to prevent buckling of the tubular member <b>1080</b> during the radial expansion of the upper portion of the tubular member. In an alternative embodiment, the locking member <b>1015</b> is omitted and the interference between the intermediate portion <b>1060</b><i>b </i>of the expansion cone launcher <b>1060</b> and the expansion cone <b>1045</b> prevents the axial displacement of the tubular member <b>1080</b> during the radial expansion of the upper portion of the tubular member.

0195As illustrated in <figref idref="DRAWINGS">FIG. 8</figref><i>g</i>, the expansion cone <b>1085</b> and <b>1100</b> may then be raised out of the wellbore <b>10</b>.

0196As illustrated in <figref idref="DRAWINGS">FIG. 8</figref><i>h</i>, the continued injection of the fluidic material <b>1125</b> into the apparatus <b>1000</b> may then cause the expansion cone launcher <b>1060</b> and the expandable tubular member <b>1080</b> to be plastically deformed and radially expanded off of the expansion cone <b>1045</b>. In this manner, the expansion cone <b>1045</b> is displaced relative to the expansion cone launcher <b>1060</b> and expandable tubular member <b>1080</b> in the axial direction. In a preferred embodiment, the axial forces created during the radial expansion process are greater than the axial forces generated by the locking device <b>1015</b>. As will be recognized by persons having ordinary skill in the art, the precise relationship between these axial forces will vary as a function of the operating characteristics of the locking device <b>1015</b> and the metallurgical properties of the expansion cone launcher <b>1060</b> and expandable tubular <b>1080</b>. In an alternative embodiment, the operating pressures of the actuating chambers, <b>1025</b><i>a </i>and <b>1025</b><i>b</i>, and the region <b>1075</b> are separately controllable by providing separate and dedicated fluid passages for pressurizing each.

0197As illustrated in <figref idref="DRAWINGS">FIG. 8</figref><i>i</i>, after completing the plastic deformation and radial expansion of the tubular member <b>1080</b>, the hardenable fluidic sealing material is allowed to cure to thereby form an annular body <b>1130</b> that provides a barrier to fluid flow into or out of the wellbore <b>10</b>. The shoe <b>1065</b> may then removed by drilling out the shoe using a conventional drilling device. A new section of the wellbore <b>10</b> may also be drilled out in order to permit additional expandable tubular members to be coupled to the bottom portion of the plastically deformed and radially expanded tubular member <b>1080</b>.

0198In an alternative embodiment, the annular body <b>1130</b> may be omitted. In several alternative embodiments, the annular body <b>1130</b> may be radially compressed before, during and/or after curing.

0199Referring to <figref idref="DRAWINGS">FIG. 8</figref><i>j</i>, the tubular member <b>1080</b> may be radially expanded again using one or more of the methods described above to provide an mono-diameter wellbore casing.

0200Referring to <figref idref="DRAWINGS">FIG. 9</figref><i>a</i>, a wellbore <b>1200</b> includes an upper preexisting casing <b>1205</b> and a lower preexisting casing <b>1210</b>. The casings, <b>1205</b> and <b>1210</b>, may further include outer annular layers of fluidic sealing materials such as, for example, cement. The ends of the casings, <b>1205</b> and <b>1210</b>, are separated by a gap <b>1215</b>.

0201Referring to <figref idref="DRAWINGS">FIG. 9</figref><i>b</i>, a tubular member <b>1220</b> may then be coupled to the opposing ends of the casings, <b>1205</b> and <b>1210</b>, to thereby bridge the gap <b>1215</b>. In a preferred embodiment, the tubular member <b>1220</b> is coupled to the opposing ends of the casings, <b>1205</b> and <b>1210</b>, by plastically deforming and radially expanding the tubular member <b>1220</b> using one or more of the methods and apparatus described and referenced above.

0202Referring to <figref idref="DRAWINGS">FIG. 9</figref><i>c</i>, a radial expansion device <b>1225</b> may then be positioned within the tubular member <b>1220</b>. In a preferred embodiment, the length of the radial expansion device <b>1225</b> is greater than or equal to the axial length of the tubular member <b>1220</b>. In several alternative embodiments, the radial expansion device <b>1225</b> may be any number of conventional radial expansion devices such as, for example, expansion cones actuated by hydraulic and/or direct axial force, roller expansion devices, and/or expandable hydraulic bladders.

0203Referring to <figref idref="DRAWINGS">FIGS. 9</figref><i>d </i>and <b>9</b><i>e</i>, after actuation and subsequent de-actuation and removal of the radial expansion device <b>1225</b>, the inside diameters of the casings, <b>1205</b> and <b>1210</b>, are substantially equal to the inside diameter of the tubular member <b>1220</b>. In this manner, a mono-diameter wellbore casing may be formed.

0204Referring to <figref idref="DRAWINGS">FIG. 10</figref>, a wellbore <b>1300</b> includes an outer tubular member <b>1305</b> and an inner tubular member <b>1310</b>. In a preferred embodiment, the tubular members, <b>1305</b> and <b>1310</b>, are plastically deformed and radially expanded using one or more of the methods and apparatus described and referenced above. In this manner, a wellbore casing may be provided whose burst and collapse strength may be precisely controlled by varying the number, thickness, and/or material properties of the tubular members, <b>1305</b> and <b>1310</b>.

0205Referring to <figref idref="DRAWINGS">FIG. 11</figref><i>a</i>, a wellbore <b>1400</b> includes a casing <b>1405</b> that is coupled to a preexisting casing <b>1410</b>. In a preferred embodiment, one or more sealing members <b>1415</b> are coupled to the exterior of the upper portion of the tubular member <b>1405</b> in order to optimally seal the interface between the tubular member <b>1405</b> and the preexisting casing <b>1410</b>. In a preferred embodiment, the tubular member <b>1405</b> is plastically deformed and radially expanded using conventional methods and/or one or more of the methods and apparatus described and referenced above. In an exemplary embodiment, the outside diameter of the tubular member <b>1405</b> prior to the radial expansion process is OD₀, the wall thickness of the tubular member <b>1405</b> prior to the radial expansion process is t₀, the outside diameter of the tubular member following the radial expansion process is OD₁, and the wall thickness of the tubular member following the radial expansion process is t₁.

0206Referring to <figref idref="DRAWINGS">FIG. 11</figref><i>b</i>, a tubular member <b>1420</b> may then be coupled to the lower portion of the tubular member <b>1405</b> by plastically deforming and radially expanding the tubular member <b>1420</b> using conventional methods and/or one or more of the methods and apparatus described and referenced above. In a preferred embodiment, the exterior surface of the upper portion of the tubular member <b>1420</b> includes one or more sealing members for sealing the interface between the tubular member <b>1420</b> and the tubular member <b>1405</b>.

0207Referring to <figref idref="DRAWINGS">FIG. 11</figref><i>c</i>, lower portion of the tubular member <b>1405</b> and the tubular member <b>1420</b> may be radially expanded again to provide a mono-diameter wellbore casing. The additional radial expansion may be provided using conventional methods and/or one or more of the methods and apparatus described and referenced above. In an exemplary embodiment, the outside diameter and wall thickness of the lower portion of the tubular member <b>1405</b> after the additional radial expansion process are OD₂and t₂.

0208The radial expansion process of <figref idref="DRAWINGS">FIGS. 11</figref><i>b</i>–<b>11</b><i>c </i>can then be repeated to provide a mono-diameter wellbore casing of virtually unlimited length.

0209In several alternative embodiments, the ordering of the radial expansions of the tubular members, <b>1405</b> and <b>1420</b>, may be changed. For example, the first tubular member <b>1405</b> may be plastically deformed and radially expanded to provide a lower portion having the outside diameter OD₂and the remaining portion having the outside diameter OD₁. The tubular member <b>1420</b> may then be plastically deformed and radially expanded one or more times until the inside diameters of the tubular members, <b>1405</b> and <b>1420</b>, are substantially equal. The plastic deformations and radial expansions of the tubular members, <b>1405</b> and <b>1420</b>, may be provided using conventional methods and/or one or more of the methods and apparatus described and referenced above.

0210In an exemplary embodiment, the total expansion strain E of the tubular member <b>1405</b> may be expressed by the following equation: <br /><i>E</i>=(<i>OD</i>₂<i>−OD</i>₀)/<i>OD</i>₀  (1)

0211where OD₀=original outside diameter; <ul id="ul0001" list-style="none"><li id="ul0001-0001" num="0000"><ul id="ul0002" list-style="none"><li id="ul0002-0001" num="0212">OD₁=outside diameter after 1^stradial expansion; and</li><li id="ul0002-0002" num="0213">OD₂=outside diameter after 2^ndradial expansion.</li></ul></li></ul>

0214Furthermore, in an exemplary embodiment, where: (1) the exterior surface of the upper portion of the tubular member <b>1420</b> includes sealing members, and (2) the radial spacing between the tubular member <b>1405</b> and the wellbore <b>1400</b> prior to the first radial expansion is equal to d, the outside diameters, OD₁and OD₂, of the tubular member <b>1405</b> following the first and second radial expansions may be expressed as: <br /><i>OD</i>₁<i>=OD</i>₀+2<i>d</i>+2<i>t</i>₁  (2)<br /><i>OD</i>₂<i>=OD</i>₁+2<i>R</i>+2<i>t</i>₂  (2)

0215where OD₀=the original outside diameter of the tubular member <b>1405</b>;

0216OD₁=the outside diameter of the tubular member <b>1405</b> following the first radial expansion;

0217OD₂=the outside diameter of the tubular member <b>1405</b> following the second radial expansion;

0218d=the radial spacing between the tubular member <b>1405</b> and the wellbore prior to the first radial expansion;

0219t₁=the wall thickness of the tubular member <b>1405</b> after the first radial expansion;

0220t₂=the wall thickness of the tubular member <b>1405</b> after the second radial expansion; and

0221R=the thickness of sealing member provided on the exterior surface of the tubular member <b>1420</b>.

0222Furthermore, in an exemplary embodiment, for d approximately equal to 0.25 inches and R approximately equal to 0.1 inches, equation (1) can be approximated as: <br /><i>E</i>=(0.7″+3.7<i>t</i>₀)/<i>OD</i>₀  (4)

0223where t₀=the original wall thickness of the tubular member <b>1405</b>.

0224In an exemplary embodiment, the total expansion strain of the tubular member <b>1405</b> should be less than or equal to 0.3 in order to maximize the burst and collapse strength of the expandable tubular member. Therefore, from equation (4) the ratio of the original outside diameter to the original wall thickness (OD₀/t₀) may be expressed as: <br /><i>OD</i>₀<i>/t</i>₀≧3.8/(0.3−0.7/<i>OD</i>₀)  (5)

0225Thus, in a preferred embodiment, for OD₀less than 10 inches, the optimal ratio of the original outside diameter to the original wall thickness (OD₀/t₀) may be expressed as: <br /><i>OD</i>₀<i>/t</i>₀≧16  (6)

0226In this manner, for typical tubular members, the burst and collapse strength of the tubular members following one or more radial expansions are maximized when the relationship in equation (6) is satisfied. Furthermore, the relationships expressed in equations (1) through (6) are valid regardless of the order or type of the radial expansions of the tubular member <b>1405</b>. More generally, the relationships expressed in equations (1) through (6) may be applied to the radial expansion of structures having a wide range of profiles such as, for example, triangular, rectangular, and oval.

0227An apparatus for plastically deforming and radially expanding a tubular member has been described that includes means for plastically deforming and radially expanding a first portion of the tubular member to a first outside diameter, and means for plastically deforming and radially expanding a second portion of the tubular member to a second outside diameter. In a preferred embodiment, the first outside diameter is greater than the second outside diameter. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the tubular member to the first outside diameter is removable. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the tubular member to the first outside diameter is frangible. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the tubular member to the first outside diameter is elastic. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the tubular member to the first outside diameter includes means for applying a radial force to the first portion of the tubular member. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the tubular member to the first outside diameter is inflatable. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the tubular member to the first outside diameter includes rolling means for applying radial pressure to the first portion of the tubular member.

0228An apparatus for plastically deforming and radially expanding a tubular member has also been described that includes a tubular support member including a first fluid passage, an expansion cone coupled to the tubular support member having a second fluid passage fluidicly coupled to the first fluid passage and an outer conical surface, a removable annular conical sleeve coupled to the outer conical surface of the expansion cone, an annular expansion cone launcher coupled to the conical sleeve and a lower portion of the tubular member, and a shoe having a valveable passage coupled to an end of the expansion cone launcher. In a preferred embodiment, the conical sleeve is frangible. In a preferred embodiment, the conical sleeve is elastic. In a preferred embodiment, the conical sleeve includes a plurality of arcuate elements.

0229A method of plastically deforming and radially expanding a tubular member has also been described that includes plastically deforming and radially expanding a portion of the tubular member to a first outside diameter, and plastically deforming and radially expanding another portion of the tubular member to a second outside diameter. In a preferred embodiment, the first diameter is greater than the second diameter. In a preferred embodiment, plastically deforming and radially expanding the portion of the tubular member includes applying a radial force to the portion of the tubular member using a conical sleeve. In a preferred embodiment, conical sleeve is frangible. In a preferred embodiment, the conical sleeve is elastic. In a preferred embodiment, the conical sleeve includes a plurality of arcuate elements. In a preferred embodiment, plastically deforming and radially expanding the portion of the tubular member includes applying a radial force to the portion of the tubular member using an inflatable bladder. In a preferred embodiment, plastically deforming and radially expanding the portion of the tubular member includes applying a radial force to the portion of the tubular member using a roller expansion device.

0230A method of coupling a first tubular member to a second tubular member has also been described that includes plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter, plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter, positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member, plastically deforming and radially expanding the second tubular member to a third outside diameter, and plastically deforming and radially expanding the second tubular member to a fourth outside diameter. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal. In a preferred embodiment, the first outside diameter is greater than the second outside diameter. In a preferred embodiment, plastically deforming and radially expanding the first portion of the first tubular member includes applying a radial force to the portion of the tubular member using a conical sleeve. In a preferred embodiment, the conical sleeve is frangible. In a preferred embodiment, the conical sleeve is elastic. In a preferred embodiment, the conical sleeve includes a plurality of arcuate elements. In a preferred embodiment, plastically deforming and radially expanding the first portion of the first tubular member includes applying a radial force to the first portion of the first tubular member using an inflatable bladder. In a preferred embodiment, plastically deforming and radially expanding the first portion of the first tubular member includes applying a radial force to the first portion of the first tubular member using a roller expansion device.

0231An apparatus for coupling a first tubular member to a second tubular member has also been described that includes means for plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter, means for plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter, means for positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member, means for plastically deforming and radially expanding the second tubular member to a third outside diameter, and means for plastically deforming and radially expanding the second tubular member to a fourth outside diameter. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal. In a preferred embodiment, the first outside diameter is greater than the second outside diameter. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the first tubular member includes means for applying a radial force to the portion of the tubular member using a conical sleeve. In a preferred embodiment, the conical sleeve is frangible. In a preferred embodiment, the conical sleeve is elastic. In a preferred embodiment, the conical sleeve includes a plurality of arcuate elements. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the first tubular member includes means for applying a radial force to the first portion of the first tubular member using an inflatable bladder. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the first tubular member includes means for applying a radial force to the first portion of the first tubular member using a roller expansion device.

0232An apparatus for forming a wellbore casing within a wellbore has also been described that includes means for supporting a tubular member within the wellbore, means for plastically deforming and radially expanding a first portion of the tubular member to a first outside diameter, and means for plastically deforming and radially expanding a second portion of the tubular member to a second outside diameter. In a preferred embodiment, the first outside diameter is greater than the second outside diameter. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the tubular member to the first outside diameter is removable. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the tubular member to the first outside diameter is frangible. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the tubular member to the first outside diameter is elastic. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the tubular member to the first outside diameter includes means for applying a radial force to the first portion of the tubular member. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the tubular member to the first outside diameter is inflatable. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the tubular member to the first outside diameter includes rolling means for applying radial pressure to the first portion of the tubular member. In a preferred embodiment, the apparatus further includes means for forming an annular body of a fluidic sealing material within an annulus between the tubular member and the wellbore.

0233An apparatus for forming a wellbore casing within a wellbore has also been described that includes a tubular support member including a first fluid passage, an expansion cone coupled to the tubular support member having a second fluid passage fluidicly coupled to the first fluid passage and an outer conical surface, a removable annular conical sleeve coupled to the outer conical surface of the expansion cone, an annular expansion cone launcher coupled to the conical sleeve and a lower portion of the tubular member, and a shoe having a valveable passage coupled to an end of the expansion cone launcher. In a preferred embodiment, the conical sleeve is frangible. In a preferred embodiment, the conical sleeve is elastic. In a preferred embodiment, the conical sleeve includes a plurality of arcuate elements.

0234A method of forming a wellbore casing within a wellbore has also been described that includes supporting a tubular member within a wellbore, plastically deforming and radially expanding a portion of the tubular member to a first outside diameter, and plastically deforming and radially expanding another portion of the tubular member to a second outside diameter. In a preferred embodiment, the first diameter is greater than the second diameter. In a preferred embodiment, plastically deforming and radially expanding the portion of the tubular member includes applying a radial force to the portion of the tubular member using a conical sleeve. In a preferred embodiment, the conical sleeve is frangible. In a preferred embodiment, the conical sleeve is elastic. In a preferred embodiment, the conical sleeve includes a plurality of arcuate elements. In a preferred embodiment, plastically deforming and radially expanding the portion of the tubular member includes applying a radial force to the portion of the tubular member using an inflatable bladder. In a preferred embodiment, plastically deforming and radially expanding the portion of the tubular member includes applying a radial force to the portion of the tubular member using a roller expansion device. In a preferred embodiment, the method further includes injecting an annular body of a hardenable fluidic sealing material into an annulus between the tubular member and the wellbore. In a preferred embodiment, the method further includes curing the annular body of hardenable fluidic sealing material.

0235A method of forming a mono-diameter wellbore casing within a wellbore has also been described that includes supporting a first tubular member within the wellbore, plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter, plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter, positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member, plastically deforming and radially expanding the second tubular member to a third outside diameter, and plastically deforming and radially expanding the second tubular member to a fourth outside diameter. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal. In a preferred embodiment, the first outside diameter is greater than the second outside diameter. In a preferred embodiment, plastically deforming and radially expanding the first portion of the first tubular member includes applying a radial force to the portion of the tubular member using a conical sleeve. In a preferred embodiment, the conical sleeve is frangible. In a preferred embodiment, the conical sleeve is elastic. In a preferred embodiment, the conical sleeve includes a plurality of arcuate elements. In a preferred embodiment, plastically deforming and radially expanding the first portion of the first tubular member includes applying a radial force to the first portion of the first tubular member using an inflatable bladder. In a preferred embodiment, plastically deforming and radially expanding the first portion of the first tubular member includes applying a radial force to the first portion of the first tubular member using a roller expansion device. In a preferred embodiment, the method further includes injecting an annular body of a hardenable fluidic sealing material into an annulus between the first tubular member and the wellbore. In a preferred embodiment, the method further includes curing the annular body of hardenable fluidic sealing material. In a preferred embodiment, the method further includes injecting an annular body of a hardenable fluidic sealing material into an annulus between the second tubular member and the wellbore. In a preferred embodiment, the method further includes curing the annular body of hardenable fluidic sealing material.

0236An apparatus for coupling a first tubular member to a second tubular member has also been described that includes means for plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter, means for plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter, means for positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member, means for plastically deforming and radially expanding the second tubular member to a third outside diameter, and means for plastically deforming and radially expanding the second tubular member to a fourth outside diameter. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal. In a preferred embodiment, the first outside diameter is greater than the second outside diameter. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the first tubular member includes means for applying a radial force to the portion of the tubular member using a conical sleeve. In a preferred embodiment, the conical sleeve is frangible. In a preferred embodiment, the conical sleeve is elastic. In a preferred embodiment, the conical sleeve includes a plurality of arcuate elements. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the first tubular member includes means for applying a radial force to the first portion of the first tubular member using an inflatable bladder. In a preferred embodiment, the means for plastically deforming and radially expanding the first portion of the first tubular member includes means for applying a radial force to the first portion of the first tubular member using a roller expansion device. In a preferred embodiment, the apparatus further includes means for injecting an annular body of a hardenable fluidic sealing material into an annulus between the first tubular member and the wellbore. In a preferred embodiment, the apparatus further includes means for curing the annular body of hardenable fluidic sealing material. In a preferred embodiment, the apparatus further includes means for injecting an annular body of a hardenable fluidic sealing material into an annulus between the second tubular member and the wellbore. In a preferred embodiment, the apparatus further includes means for curing the annular body of hardenable fluidic sealing material.

0237An apparatus for plastically deforming and radially expanding a tubular member has also been described that includes means for providing a lipped portion in a portion of the tubular member, and means for plastically deforming and radially expanding another portion of the tubular member.

0238An apparatus for plastically deforming and radially expanding a tubular member has also been described that includes a tubular support member including a first fluid passage, an expansion cone coupled to the tubular support member having a second fluid passage fluidicly coupled to the first fluid passage and an outer conical surface, an annular expansion cone launcher including: a first annular portion coupled to a lower portion of the tubular member, a second annular portion coupled to the first annular portion that mates with the outer conical surface of the expansion cone, a third annular portion coupled to the second annular portion having a first outside diameter, and a fourth annular portion coupled to the third annular portion having a second outside diameter, wherein the second outside diameter is less than the first outside diameter, and a shoe having a valveable passage coupled to fourth annular portion of the expansion cone launcher.

0239A method of plastically deforming and radially expanding a tubular member has also been described that includes providing a lipped portion in a portion of the tubular member, and plastically deforming and radially expanding another portion of the tubular member.

0240A method of coupling a first tubular member to a second tubular member has also been described that includes providing a lipped portion in a portion of the first tubular member, plastically deforming and radially expanding another portion of the first tubular member, positioning the second tubular member inside the first tubular member in overlapping relation to the lipped portion of the first tubular member, and plastically deforming and radially expanding the second tubular member. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal.

0241An apparatus for coupling a first tubular member to a second tubular member has also been described that includes means for providing a lipped in the first tubular member, means for plastically deforming and radially expanding another portion of the first tubular member, means for positioning the second tubular member inside the first tubular member in overlapping relation to the lipped portion of the first tubular member, and means for plastically deforming and radially expanding the second tubular member. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal.

0242An apparatus for forming a wellbore casing within a wellbore has also been described that includes means for supporting a tubular member within the wellbore, means for providing a lipped portion in the tubular member, and means for plastically deforming and radially expanding another portion of the tubular member to a second outside diameter.

0243An apparatus for forming a wellbore casing within a wellbore has also been described that includes a tubular support member including a first fluid passage, an expansion cone coupled to the tubular support member having a second fluid passage fluidicly coupled to the first fluid passage and an outer conical surface, an annular expansion cone launcher including: a first annular portion coupled to a lower portion of the tubular member, a second annular portion coupled to the first annular portion that mates with the outer conical surface of the expansion cone, a third annular portion coupled to the second annular portion having a first outside diameter, and a fourth annular portion coupled to the third annular portion having a second outside diameter, wherein the second outside diameter is less than the first outside diameter, and a shoe having a valveable passage coupled to fourth annular portion of the expansion cone launcher.

0244A method of forming a wellbore casing in a wellbore has also been described that includes supporting a tubular member within the wellbore, providing a lipped portion in a portion of the tubular member, and plastically deforming and radially expanding another portion of the tubular member. In a preferred embodiment, the method further includes injecting a hardenable fluidic sealing material in an annulus between the tubular member and the wellbore. In a preferred embodiment, the method further includes curing the fluidic sealing material.

0245A method of forming a mono-diameter wellbore casing within a wellbore has also been described that includes supporting a first tubular member within the wellbore, providing a lipped portion in a portion of the first tubular member, plastically deforming and radially expanding another portion of the first tubular member, positioning the second tubular member inside the first tubular member in overlapping relation to the lipped portion of the first tubular member, and plastically deforming and radially expanding the second tubular member. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal. In a preferred embodiment, the method further includes injecting a hardenable fluidic sealing material in an annulus between the first tubular member and the wellbore. In a preferred embodiment, the method further includes curing the fluidic sealing material. In a preferred embodiment, the method further includes injecting a hardenable fluidic sealing material in an annulus between the second tubular member and the wellbore. In a preferred embodiment, the method further includes curing the fluidic sealing material.

0246An apparatus for forming a mono-diameter wellbore casing within a wellbore has also been described that includes means for providing a lipped in the first tubular member, means for plastically deforming and radially expanding another portion of the first tubular member, means for positioning the second tubular member inside the first tubular member in overlapping relation to the lipped portion of the first tubular member, and means for plastically deforming and radially expanding the second tubular member. The inside diameters of the first and second tubular-members after the plastic deformations and radial expansions are substantially equal. In a preferred embodiment, the apparatus further includes means for injecting a hardenable fluidic sealing material in an annulus between the first tubular member and the wellbore. In a preferred embodiment, the apparatus further includes means for curing the fluidic sealing material. In a preferred embodiment, the apparatus further includes means for injecting a hardenable fluidic sealing material in an annulus between the second tubular member and the wellbore. In a preferred embodiment, the apparatus further includes means for curing the fluidic sealing material.

0247An apparatus for plastically deforming and radially expanding a tubular member has also been described that includes means for plastically deforming and radially expanding a first end of the tubular member, and means for plastically deforming and radially expanding a second end of the tubular member. In a preferred embodiment, the apparatus further includes means for anchoring the tubular member during the radial expansion.

0248An apparatus for plastically deforming and radially expanding a tubular member has also been described that includes a tubular support member including a first passage, an expansion cone coupled to the tubular support having a second passage fluidicly coupled to the first passage and an outer conical surface, an annular expansion cone launcher movably coupled to outer conical surface of the expansion cone, an expandable tubular member coupled to an end of the annular expansion cone launcher, a shoe coupled to another end of the annular expansion cone launcher having a valveable fluid passage, and another annular expansion cone movably coupled to the tubular support member. The annular expansion cones are positioned in opposite orientations. In a preferred embodiment, the annular expansion cone is adapted to plastically deform and radially expand a first end of the expandable tubular member and the other annular expansion cone is adapted to plastically deform and radially expand a second end of the expandable tubular member. In a preferred embodiment, the apparatus further includes an anchoring member coupled to the tubular support member adapted to hold the expandable tubular.

0249A method of plastically deforming and radially expanding a tubular member has also been described that includes plastically deforming and radially expanding a first end of the tubular member, and plastically deforming and radially expanding a second end of the tubular member. In a preferred embodiment, the method further includes anchoring the tubular member during the radial expansion. In a preferred embodiment, the first end of the tubular member is plastically deformed and radially expanded before the second end. In a preferred embodiment, plastically deforming and radially expanding the second end of the tubular member includes injecting a fluidic material into the tubular member.

0250A method of coupling a first tubular member to a second tubular member has also been described that includes positioning the second tubular member inside the first tubular member in an overlapping relationship, plastically deforming and radially expanding the end of the second tubular member that overlaps with the first tubular member, and plastically deforming and radially expanding the remaining portion of the second tubular member. In a preferred embodiment, the method further includes plastically deforming and radially expanding at least a portion of the second tubular member. In a preferred embodiment, the inside diameters of the first and second tubular members are substantially equal after the radial expansions.

0251An apparatus for coupling a first tubular member to a second tubular member has also been described that includes means for positioning the second tubular member inside the first tubular member in an overlapping relationship, means for plastically deforming and radially expanding the end of the second tubular member that overlaps with the first tubular member, and means for plastically deforming and radially expanding the remaining portion of the second tubular member. In a preferred embodiment, the apparatus further includes means for plastically deforming and radially expanding at least a portion of the second tubular member. In a preferred embodiment, the inside diameters of the first and second tubular members are substantially equal after the radial expansions.

0252An apparatus for forming a wellbore casing within a wellbore has also been described that includes means for supporting a tubular member within the wellbore, means for plastically deforming and radially expanding a first end of the tubular member, and means for plastically deforming and radially expanding a second end of the tubular member. In a preferred embodiment, the apparatus further includes means for anchoring the tubular member during the radial expansion. In a preferred embodiment, the apparatus further includes means for injecting a hardenable fluidic sealing material into an annulus between the tubular member and the wellbore.

0253An apparatus for forming a wellbore casing within a wellbore has also been described that includes a tubular support member including a first passage, an expansion cone coupled to the tubular support having a second passage fluidicly coupled to the first passage and an outer conical surface, an annular expansion cone launcher movably coupled to outer conical surface of the expansion cone, an expandable tubular member coupled to an end of the annular expansion cone launcher, a shoe coupled to another end of the annular expansion cone launcher having a valveable fluid passage, and another annular expansion cone movably coupled to the tubular support member. The annular expansion cones are positioned in opposite orientations. In a preferred embodiment, the annular expansion cone is adapted to plastically deform and radially expand a first end of the expandable tubular member and the other annular expansion cone is adapted to plastically deform and radially expand a second end of the expandable tubular member. In a preferred embodiment, the apparatus further includes an anchoring member coupled to the tubular support member adapted to hold the expandable tubular.

0254A method of forming a wellbore casing within a wellbore has also been described that includes plastically deforming and radially expanding a first end of the tubular member, and plastically deforming and radially expanding a second end of the tubular member. In a preferred embodiment, the method further includes anchoring the tubular member during the radial expansion. In a preferred embodiment, the first end of the tubular member is plastically deformed and radially expanded before the second end. In a preferred embodiment, plastically deforming and radially expanding the second end of the tubular member includes injecting a fluidic material into the tubular member. In a preferred embodiment, the method further includes injecting a hardenable fluidic sealing material into an annulus between the tubular member and the wellbore.

0255A method of forming a wellbore casing within a wellbore has also been described that includes plastically deforming and radially expanding a first tubular member within the wellbore, positioning a second tubular member inside the first tubular member in an overlapping relationship, plastically deforming and radially expanding the end of the second tubular member that overlaps with the first tubular member, plastically deforming and radially expanding the remaining portion of the second tubular member. In a preferred embodiment, the method further includes plastically deforming and radially expanding at least a portion of the second tubular member. In a preferred embodiment, the inside diameters of the first and second tubular members are substantially equal after the radial expansions. In a preferred embodiment, the method further includes injecting a hardenable fluidic sealing material into an annulus between the first tubular member and the wellbore. In a preferred embodiment, the method further includes injecting a hardenable fluidic sealing material into an annulus between the second tubular member and the wellbore.

0256An apparatus for forming a wellbore casing within a wellbore has also been described that includes means for plastically deforming and radially expanding a first tubular member within the wellbore, means for positioning the second tubular member inside the first tubular member in an overlapping relationship, means for plastically deforming and radially expanding the end of the second tubular member that overlaps with the first tubular member, means for plastically deforming and radially expanding the remaining portion of the second tubular member. In a preferred embodiment, the apparatus further includes means for plastically deforming and radially expanding at least a portion of the second tubular member. In a preferred embodiment, the inside diameters of the first and second tubular members are substantially equal after the radial expansions. In a preferred embodiment, the apparatus further includes means for injecting a hardenable fluidic sealing material into an annulus between the first tubular member and the wellbore. In a preferred embodiment, the apparatus further includes means for injecting a hardenable fluidic sealing material into an annulus between the second tubular member and the wellbore.

0257An apparatus for bridging an axial gap between opposing pairs of wellbore casing within a wellbore has also been described that includes means for supporting a tubular member in overlapping relation to the opposing ends of the wellbore casings, means for plastically deforming and radially expanding the tubular member, and means for plastically deforming and radially expanding the tubular member and the opposing ends of the wellbore casings.

0258A method of bridging an axial gap between opposing pairs of wellbore casing within a wellbore has also been described that includes supporting a tubular member in overlapping relation to the opposing ends of the wellbore casings, plastically deforming and radially expanding the tubular member, and <ul id="ul0003" list-style="none"><li id="ul0003-0001" num="0000"><ul id="ul0004" list-style="none"><li id="ul0004-0001" num="0259">plastically deforming and radially expanding the tubular member and the opposing ends of the wellbore casings.</li></ul></li></ul>

0260A method of forming a structure having desired strength characteristics has also been described that includes providing a first tubular member, and plastically deforming and radially expanding additional tubular members onto the interior surface of the first tubular member until the desired strength characteristics are achieved.

0261A method of forming a wellbore casing within a wellbore having desired strength characteristics has also been described that includes plastically deforming and radially expanding a first tubular member within the wellbore, and plastically deforming and radially expanding additional tubular members onto the interior surface of the first tubular member until the desired strength characteristics are achieved.

0262A method of coupling a first tubular member to a second tubular member, the first tubular member having an original outside diameter OD₀and an original wall thickness t₀, has also been described that includes plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter, plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter, positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member, plastically deforming and radially expanding the second tubular member to a third outside diameter, and plastically deforming and radially expanding the second tubular member to a fourth outside diameter, wherein the inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal, and <ul id="ul0005" list-style="none"><li id="ul0005-0001" num="0000"><ul id="ul0006" list-style="none"><li id="ul0006-0001" num="0263">wherein the ratio of the original outside diameter OD₀of the first tubular member to the original wall thickness t₀of the first tubular member is greater than or equal to 16.</li></ul></li></ul>

0264A method of forming a mono-diameter wellbore casing has also been described that includes positioning a first tubular member within a wellbore, the first tubular member having an original outside diameter OD₀and an original wall thickness t₀, plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter, plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter, positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member, plastically deforming and radially expanding the second tubular member to a third outside diameter, and plastically deforming and radially expanding the second tubular member to a fourth outside diameter. The inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal, and wherein the ratio of the original outside diameter OD₀of the first tubular member to the original wall thickness t₀of the first tubular member is greater than or equal to 16.

0265An apparatus has also been described that includes a plastically deformed and radially expanded tubular member having a first portion having a first outside diameter and a remaining portion having a second outside diameter, wherein the ratio of the original outside diameter OD₀of the first tubular member to the original wall thickness t₀of the first tubular member is greater than or equal to 16.

0266An apparatus has also been described that includes a plastically deformed and radially expanded first tubular member having a first portion having a first outside diameter and a remaining portion having a second outside diameter, and a plastically deformed and radially expanded second tubular member coupled to the first portion of the first tubular member. The ratio of the original outside diameter OD₀of the first tubular member to the original wall thickness t₀of the first tubular member is greater than or equal to 16. In a preferred embodiment, the inside diameters of the first and second tubular members are substantially equal.

0267A wellbore casing formed in a wellbore has also been described that includes a plastically deformed and radially expanded first tubular member having a first portion having a first outside diameter and a remaining portion having a second outside diameter, and a plastically deformed and radially expanded second tubular member coupled to the first portion of the first tubular member. The ratio of the original outside diameter OD₀of the first tubular member to the original wall thickness t₀of the first tubular member is greater than or equal to 16. In a preferred embodiment, the inside diameters of the first and second tubular members are substantially equal.

0268An apparatus has also been described that includes a plastically deformed and radially expanded tubular member. In a preferred embodiment, the ratio of the original outside diameter OD₀of the tubular member to the original wall thickness t₀of the tubular member is greater than or equal to 16.

0269In several alternative embodiments, the methods and apparatus described and referenced above may be used to form or repair wellbore casings, pipelines, and structural supports.

0270Although this detailed description has shown and described illustrative embodiments of the invention, this description contemplates a wide range of modifications, changes, and substitutions. In some instances, one may employ some features of the present invention without a corresponding use of the other features. Accordingly, it is appropriate that readers should construe the appended claims broadly, and in a manner consistent with the scope of the invention.